US20090199632A1 - Sensor apparatus and method of manufacturing the same - Google Patents
Sensor apparatus and method of manufacturing the same Download PDFInfo
- Publication number
- US20090199632A1 US20090199632A1 US12/320,957 US32095709A US2009199632A1 US 20090199632 A1 US20090199632 A1 US 20090199632A1 US 32095709 A US32095709 A US 32095709A US 2009199632 A1 US2009199632 A1 US 2009199632A1
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- United States
- Prior art keywords
- sensor chip
- housing
- side wall
- clearance
- adhesive member
- Prior art date
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- Granted
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Classifications
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01F—MEASURING VOLUME, VOLUME FLOW, MASS FLOW OR LIQUID LEVEL; METERING BY VOLUME
- G01F15/00—Details of, or accessories for, apparatus of groups G01F1/00 - G01F13/00 insofar as such details or appliances are not adapted to particular types of such apparatus
- G01F15/18—Supports or connecting means for meters
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01F—MEASURING VOLUME, VOLUME FLOW, MASS FLOW OR LIQUID LEVEL; METERING BY VOLUME
- G01F1/00—Measuring the volume flow or mass flow of fluid or fluent solid material wherein the fluid passes through a meter in a continuous flow
- G01F1/68—Measuring the volume flow or mass flow of fluid or fluent solid material wherein the fluid passes through a meter in a continuous flow by using thermal effects
- G01F1/684—Structural arrangements; Mounting of elements, e.g. in relation to fluid flow
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01F—MEASURING VOLUME, VOLUME FLOW, MASS FLOW OR LIQUID LEVEL; METERING BY VOLUME
- G01F1/00—Measuring the volume flow or mass flow of fluid or fluent solid material wherein the fluid passes through a meter in a continuous flow
- G01F1/68—Measuring the volume flow or mass flow of fluid or fluent solid material wherein the fluid passes through a meter in a continuous flow by using thermal effects
- G01F1/684—Structural arrangements; Mounting of elements, e.g. in relation to fluid flow
- G01F1/688—Structural arrangements; Mounting of elements, e.g. in relation to fluid flow using a particular type of heating, cooling or sensing element
- G01F1/69—Structural arrangements; Mounting of elements, e.g. in relation to fluid flow using a particular type of heating, cooling or sensing element of resistive type
- G01F1/692—Thin-film arrangements
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01F—MEASURING VOLUME, VOLUME FLOW, MASS FLOW OR LIQUID LEVEL; METERING BY VOLUME
- G01F15/00—Details of, or accessories for, apparatus of groups G01F1/00 - G01F13/00 insofar as such details or appliances are not adapted to particular types of such apparatus
- G01F15/14—Casings, e.g. of special material
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L2224/00—Indexing scheme for arrangements for connecting or disconnecting semiconductor or solid-state bodies and methods related thereto as covered by H01L24/00
- H01L2224/01—Means for bonding being attached to, or being formed on, the surface to be connected, e.g. chip-to-package, die-attach, "first-level" interconnects; Manufacturing methods related thereto
- H01L2224/42—Wire connectors; Manufacturing methods related thereto
- H01L2224/47—Structure, shape, material or disposition of the wire connectors after the connecting process
- H01L2224/48—Structure, shape, material or disposition of the wire connectors after the connecting process of an individual wire connector
- H01L2224/4805—Shape
- H01L2224/4809—Loop shape
- H01L2224/48091—Arched
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49007—Indicating transducer
Definitions
- the present invention relates to a sensor apparatus including an insulating material that covers a terminal for outputting a signal from an exposed sensing member to an external element.
- the present invention also relate to a method of manufacturing such a sensor apparatus.
- JP-A-2007-33411 corresponding to US Patent Application Publication No. 2007/0022808 proposes a method of manufacturing such a senor apparatuses that includes an insulating material that covers a terminal for outputting a signal from an exposed sensing member to an external element.
- a sensor apparatus is manufactured through: attaching a buffer member made of rubber to a boundary part of a region where a molded member is to cover; deforming the buffering member in closing a mold; and filling a ditch between a sensor chip and a support member to prevent a molding material from leaking toward a sensing member in injection molding.
- the buffer member is so tiny, the buffer member and a part to which the buffer member is attached are required to have high dimensional accuracy, and thus, it is difficult to improve a production yield of the sensor apparatus. Further, since the buffer member is required to be attached with high accuracy, it is difficult to improve production efficiency of the sensor apparatus.
- a method of manufacturing a sensor apparatus includes: preparing a sensor chip including a substrate, a sensing member located on the substrate and a terminal located on the substrate, the terminal outputting a signal from the sensing member; and preparing a housing having (i) a first opening on a front surface thereof, (ii) an inner side wall defining a receive space therein communicating with the first opening, and (iii) a bonding member located on an inner bottom surface of the housing at a boundary part of a predetermined portion.
- the inner bottom surface defines a bottom of the receive space, and a depth defined between the first opening and the bonding member is deeper compared to a thickness of the sensor chip.
- the method further includes: placing an adhesive member on one of the bonding member and a back surface of the sensor chip; and placing the sensor chip in the receive space through the first opening so that the sensing member is exposed.
- the placing of the sensor chip includes placing the back surface of the sensor chip on the bonding member via the adhesive member to form a clearance between a side surface of the sensor chip and the inner side wall of the housing.
- the method further includes pressing the front surface of the sensor chip whose back surface is placed on the bonding member, so that: the sensor chip and the housing push the adhesive member to the clearance; and the front surface of the sensor chip, the front surface of the housing and a surface of a part of the adhesive member pushed in the clearance are in a same plane at the boundary part.
- the method further includes: electrically connecting the terminal to an electrical conductive member, the electrical conductive member to be electrically connected to an external element; and forming, by injection molding, a molded member that covers the predetermined portion including a connection part where the terminal and the electric conductive member are connected with each other.
- the forming of the molded member includes: closing a mold receiving the sensor chip, the housing and the electric conductive member, after the pressing of the front surface of the sensor chip and the electrically connecting of the terminal; and injecting a molding material in the mold.
- a method of manufacturing a sensor apparatus includes: preparing a sensor chip including a substrate, a sensing member located on the substrate and a terminal located on the substrate, the terminal outputting a signal from the sensing member; preparing a housing having (i) a first opening on a front surface of the housing, (ii) an inner side wall defining a receive space therein communicating with the first opening, and (iii) a bonding member located on an inner bottom surface of the housing at a boundary part of a predetermined portion.
- the inner bottom surface defines a bottom of the receive space, and a depth defined between the first opening and the bonding member is deeper compared to a thickness of the sensor chip.
- the method further includes: placing an adhesive member on one of the bonding member and a back surface of the sensor chip; and placing the sensor chip in the receive space through the first opening so that the sensing member is exposed.
- the placing of the sensor chip includes: placing the back surface of the sensor chip on the bonding member via the adhesive member to form a clearance between a side surface of the sensor chip and the inner side wall of the housing.
- the method further includes: pressing the front surface of the sensor chip whose back surface is placed on the bonding member, so that the sensor chip and the housing push the adhesive member to the clearance; electrically connecting the terminal to an electrical conductive member, the electrical conductive member to be electrically connected to an external element; placing a film on the front surface of the sensor chip and the front surface of the housing so that the film covers the boundary part of the predetermined portion, after the pressing of the front surface of the sensor chip and the electrically connecting of the terminal; and forming, by injection molding, a molded member that covers the predetermined portion including a connection part where the terminal and the electric conductive member are connected with each other.
- the forming of the molded member includes: closing a mold receiving the sensor chip, the housing and the electric conductive member, after the pressing of the front surface of the sensor chip and the electrically connecting of the terminal; and injecting a molding material in the mold.
- the irregularities is filled with the film. Therefore, in the forming of the molded member covering the predetermined portion by injection molding, there is not a gap, at the boundary part of the predetermined portion, between: the mold; and the front surface of the sensor chip, the surface of the part of the adhesive member and the front surface of the housing. Thus, it is possible to prevent the molding material from leaking to an outside of the predetermined portion. Accordingly, it is possible to improve a production yield and production efficiency of the senor apparatus.
- a sensor apparatus includes a sensor chip, a housing, an electric conductive member and a molded member.
- the sensor chip includes a substrate, a sensing member located on the substrate, and a terminal located on the substrate.
- the housing receives the sensor chip with the sensing member of the sensor chip being exposed.
- the electric conductive member is electrically connected with the terminal and to be electrically connected with an external element.
- the molded member covering a covered portion includes a connection portion where the terminal and the electric conductive member are connected with each other.
- the housing has a first opening on a front surface thereof.
- the housing defines a receive space therein (i) communicating with the first opening and (ii) receiving the sensor chip through the first opening while the housing and a side surface of the sensor chip define a clearance therebetween.
- the housing further has a bonding member.
- the bonding member is located on an inner bottom surface of the housing at a place corresponding to a boundary part of the covered portion, the inner bottom surface defining a bottom of the receive space.
- the bonding member is bonded to a back surface of the sensor chip via an adhesive member.
- the first opening and the bonding member define therebetween a depth, the depth being deeper compared to a thickness of the sensor chip.
- a part of the adhesive member is located in the clearance by being pressed and pushed out by the sensor chip and the housing.
- the front surface of the housing, a surface of the part of the adhesive member, and a front surface of the sensor chip are in a same plane at the boundary part.
- the above sensor apparatus in the forming of the molded member covering the covered portion by injection molding, there is not a gap, at the boundary part of the covered portion, between: a mold; and the front surface of the sensor chip, the surface of the part of the adhesive member and the front surface of the housing.
- a mold in the forming of the molded member covering the covered portion by injection molding, there is not a gap, at the boundary part of the covered portion, between: a mold; and the front surface of the sensor chip, the surface of the part of the adhesive member and the front surface of the housing.
- FIG. 1A is a plan view diagram illustrating a heat type flow amount sensor apparatus in accordance with an exemplary embodiment
- FIG. 1B is a cross sectional diagram taken along line IB-IB of FIG. 1A ;
- FIG. 1C is a cross sectional diagram taken along line IC-IC of FIG. 1A ;
- FIG. 2A is a plan view diagram illustrating a sensor chip of a heat type flow amount sensor apparatus exemplified in FIG. 1A ;
- FIG. 2B is a cross sectional diagram taken along line IIB-IIB of FIG. 2A ;
- FIG. 3A is a plan view diagram illustrating a housing of a heat type flow amount sensor apparatus exemplified in FIG. 1A ;
- FIG. 3B is a cross sectional diagram taken along line IIIB-IIIB of FIG. 3A ;
- FIG. 4 is a plan view diagram illustrating a sensor chip and a housing which define a clearance therebetween;
- FIG. 5 is a plan view diagram illustrating a sensor chip.
- FIG. 6 is a process chart illustrating a manufacturing flow
- FIG. 7A is a plan view diagram corresponding to S 3 in FIG. 6 and illustrating a housing in which an adhesive member is placed;
- FIG. 7B is a cross sectional diagram taken along line VIIB-VIIB in FIG. 7A ;
- FIG. 8A is a plan view diagram corresponding to S 3 and S 4 in FIG. 6 and illustrating the pressing of a sensor chip by a pressing member;
- FIG. 8B is a cross sectional diagram taken along line VIIIB-VIIIB in FIG. 8A ;
- FIG. 9A is a plan view diagram corresponding to S 4 in FIG. 6 and illustrating a state where a sensor chip is pressed by a pressing member;
- FIG, 9 B is a cross sectional diagram taken along line IXB-IXB in FIG. 9A ;
- FIG. 10A is a plan view diagram corresponding to S 5 in FIG. 6 and illustrating a state where a lead is connected to a sensor chip by wiring;
- FIG. 10B is a cross sectional diagram taken along line XB-XB in FIG. 10A ;
- FIGS. 11A and 11B are cross sectional diagrams each corresponding to S 7 in FIG. 6 ;
- FIG. 11C is a cross sectional diagram corresponding to S 8 in FIG. 6 ;
- FIG. 11D is a cross sectional diagram illustrating a heat type flow amount sensor apparatus manufactured
- FIG. 12A is a cross sectional diagram illustrating a surface flaw formed on a housing
- FIG. 12B is a cross sectional diagram illustrating a film placed on a housing
- FIG. 12C is a cross sectional diagram illustrating a state where a surface flaw is filled with a film
- FIG. 13A is a plan view diagram illustrating a relief portion in accordance with a first modification of the exemplary embodiment
- FIG. 13B is a cross sectional diagram taken along line XIIIB-XIIIB in FIG. 13A ;
- FIG. 14 is a plan view diagram illustrating a relief portion in accordance with a second modification of the exemplary embodiment
- FIG. 15 is a plan view diagram illustrating a relief portion in accordance with a third modification of the exemplary embodiment
- FIG. 16 is a plan view diagram illustrating a relief portion in accordance with a fourth modification of the exemplary embodiment
- FIG. 17A a cross sectional diagram illustrating an adhesive member prior to pressing in accordance with a fifth modification of the exemplary embodiment.
- FIG. 17B a cross sectional diagram illustrating the adhesive member after the pressing in accordance with the fifth modification of the exemplary embodiment.
- a heat type flow amount sensor apparatus 100 includes a sensor chip 30 for detecting a flow amount of air, a housing 40 for receiving the senor chip 30 , multiple wires 60 , multiple leads 70 , and a molded member 50 .
- the multiple wires 60 are electrically connected with the sensor chip 30 by wire bonding and function as an electric conductive member.
- the multiple leads 70 are electrically connected to the multiple wires 60 , respectively.
- the molded member 50 is formed by molding using a molding material, and covers a connection part where the multiple lead 70 and the multiple wire are connected with each other. Alternatively, the multiple leads 70 may be an external element 70 .
- the sensor chip 30 is formed using a semiconductor substrate 30 a and formed in a thin-walled plate shape.
- the sensor chip 30 includes a sensing member 32 for sensing a flow amount of air.
- the sensing member 32 is located on a front surface 30 b of the semiconductor substrate 30 a and located near a side surface 36 d (i.e., a fourth side surface) of the sensor chip 30 .
- the sensor chip 30 further includes multiple pads 34 that function as a terminal 34 .
- the multiple pad 34 are located on the front surface 30 b, located near a side surface 36 c (i.e., a third side surface) of the sensor chip 30 , and aligned along the side surface 36 c.
- a side surface 36 d side is also referred on a first end side
- a side surface 36 c side is also referred on a second end side.
- the pads 34 are electrically connected with the leads 70 through the wires 60 , respectively.
- the leads 70 are electrically connected to a control circuit (not shown) which performs a control operation based on a signal from the sensing member 32 .
- the sensing member 32 has a cavity 35 on a back surface thereof.
- the sensing member 32 includes a membrane member 31 having a thin insulating film on a surface defining the cavity 35 .
- a silicon substrate 30 a is used as the semiconductor substrate 30 a since an insulating layer or a conductive layer can be easily formed and processed.
- the cavity 35 is formed through etching the back surface of the semiconductor substrate 30 a, and thereby to form the membrane member 31 , since processing can be easily performed.
- the molded member 50 is formed through injection molding with epoxy resin, taking into account high dimensional stability, high resistance to water and chemical, and high electric insulation.
- the housing 40 is formed through processing (e.g., etching) the same material as that used for the leads 70 , since it becomes possible to improve production efficiency.
- the housing 40 is formed in a generally frame shape and defines a receive space 41 (i.e., receive portion 41 ) for receiving the sensor chip 30 .
- An opening 45 a i.e., a first opening
- Another opening 45 b i.e., a second opening
- the openings 45 a, 45 b are in communication with the receive space 41 .
- the housing 40 has a bonding member 44 located on a part of the bottom of the receive space 41 on the second end side. The bonding member 44 is bonded to a part of the back surface of the sensor chip 30 on the second end side.
- the bonding member 44 extends from a lower part of an inner side wall 42 c, which is located on the second end side, of the housing 40 toward the first end side of the housing 40 .
- a surface 44 a of the bonding member 44 is formed in a shape corresponding to the part of the back surface of the sensor chip 30 on the second end side.
- the sensor chip 30 is received in the receive space 41 .
- the part of the back surface of the sensor chip 30 on the second end side is bonded to the surface 44 a of the bonding member 44 using an adhesive member 80 .
- the sensor chip 30 is cantilevered in the receive space 41 ; a bonded end of the sensor chip 30 is supported and the other end is a free end.
- a depth “D 2 ” from an upper end of the opening 45 a to the surface 44 a of the bonding member 44 is designed deeper compared to a thickness “D 1 ” of the sensor chip 30 .
- the depth “D 2 ” is designed such that, when the part of the back surface of the sensor chip 30 on the second end side is placed on the surface 44 a of the bonding member 44 via the adhesive member (referred by the reference numeral 80 in FIG. 1A to 1C ), the front surface of the sensor chip 30 projects from or positioned above the front surface of the housing 40 .
- the depth “D 2 ” is designed such that, when the adhesive member 80 placed on the surface 44 a of the adhesive member 80 is pressed and deformed through pressing the front surface of the sensor chip 30 , the front surface of the sensor chip 30 and the front surface of the housing 40 can become in the same plane.
- the receive space 41 is formed to have such a size that the sensor chip 30 can be accommodated in the receive space 41 through the opening 45 a while the back surface of the sensor chip 30 is being directed to the bonding member 44 . As shown in FIG. 4 , the receive space 41 has a size such that a clearance is formed between an inner side wall of the housing defining the receive space 41 and a side surface of the sensor chip 30 received in the receive space.
- a clearance 43 a is formed between a first part of a side surface 36 a of the sensor chip 30 and a first part of an inner side wall 42 a of the housing 40 , which face each other.
- the side surface 36 a is generally parallel to a longer side direction of the sensor chip 30 .
- the first part of the side surface 36 a is located closer to the pad 34 than the other part of the side surface 36 a is, and, the first part of the side surface 36 a extends to the bonding member 44 .
- a clearance 43 b is formed between a first part of a side surface 36 b of the sensor chip 30 and a first part of an inner side wall 42 b of the housing 40 , which face each other.
- the side surface 36 a and the side surface 36 b of the sensor chip 30 are positioned opposite to each other.
- the first part of the side surface 36 b is located closer to the pad 34 than the other part of the side surface 36 b is. Also, the first part of the side surface 36 b extends to the bonding member 44 .
- a clearance 43 e is formed between a second part of the side surface 36 a of the sensor chip 30 and a second part of the inner side wall 42 a of the housing 40 , which face each other.
- the second part of the side surface 36 a is located closer to the sensing member 32 than the first part of the side surface 36 a is.
- a clearance 43 f is formed between a second part of the side surface 36 b of the sensor chip 30 and a second part of the inner side wall 42 b of the housing 40 , which face each other.
- the second part of the side surface 36 b is located closer to the sensing member 32 than the first part of the side surface 36 b is.
- Another clearance 43 c is formed between a side surface 36 c of the sensor chip 30 and an inner side wall 42 c of the housing 40 , which face each other.
- the side surface 36 c is located on a pad 34 side.
- Another clearance 43 d is formed between a side surface 36 d of the sensor chip 30 and an inner side wall 42 d of the housing 40 , which face each other.
- the side surface 36 d is located on a sensing member 32 side.
- a relief portion 41 a (i.e., an in-flow portion 41 a ) is formed between the side surface 36 a of the sensor chip 30 and the inner side wall 42 a of the housing 40 , which face each other.
- a relief portion 41 b (i.e., an in-flow portion 41 b ) is formed between the side surface 36 b of the sensor chip 30 and the inner side wall 42 b of the housing 40 , which face each other.
- the relief portions 41 a, 41 b are designed so that the adhesive member 80 can flow into the relief portions 41 a, 41 b.
- the side surfaces 36 a, 36 b of are continuously connected with two ends of the side surface 36 c, which is located on a pad 34 side.
- the relief portions 41 a, 41 b are respectively formed on the inner side walls 42 a, 42 b, each of which extends across a boundary part 50 b of a covered portion 50 a of the molded member 50 (see FIG. 1A ).
- the relief portion 41 a, 41 b provides a space for receiving the adhesive member 80 that is pushed out to the clearance 43 , when the front surface 30 b of the sensor chip 30 is pressed, by a back surface of the second end part of the sensor chip 30 and the surface 44 a of the bonding member 44 .
- the relief portions 41 a, 41 b are formed at positions so as to prevent the adhesive member 80 flowing into the clearance 43 from reaching to the vicinity of the sensing member 32 . Further, the relief portions 41 a, 41 b are formed to have volumes enough to prevent the extra adhesive member 80 flowing into the clearance 43 from flowing to the vicinity of the sensing member 32 via the relief portions 41 a, 41 b.
- the relief portions 41 a, 41 b are respectively formed and defined by concaved surfaces of the inner side walls 42 a, 42 b.
- the adhesive member 80 that had flowed in the clearance 43 partially exists in the relief portions 41 a, 41 b.
- the adhesive member 80 projects from an end face of the bonding member 44 .
- the inner side wall defining each relief portion 41 a, 41 b has a circular arc shape in a plan view.
- the relief portions 41 a, 41 b are located symmetrically with respect to the receive space 41 .
- a throttle portion 47 a is formed on the inner side wall 42 a of the housing 40 , located between the clearance 43 a and the relief portion 41 a, and located adjacent to the relief portion 41 a.
- a throttle 47 b is formed between the clearance 43 b and the relief portion 41 b, and located adjacent to the relief portion 41 b. That is, the throttle portions 47 a, 47 b are respectively formed in conduction path of the adhesive member 80 from the clearances 43 a, 43 b to the relief portions 41 a, 41 b.
- the throttle portions 47 a, 47 b can throttle flows of the adhesive member 80 from the clearances 43 a, 43 b toward the relief portions 41 a, 41 b, respectively. That is, the throttle portion 47 a, 47 b limits a flow of the adhesive member 80 to reduce an amount of the adhesive member 80 flowing to the relief portion 41 a, 41 b, and thereby to increase an amount of the adhesive member 80 flowing to the clearances 43 a, 43 b, 43 c. Thereby, the adhesive member 80 can move upward in the clearances 43 a, 43 b, 43 c, and can reach upper ends of the clearances 43 a, 43 b, 43 c.
- the throttle portion 47 a, 47 b can also function as a positioning member for positioning the sensor chip 30 when the sensor chip 30 is accommodated in the receive space 41
- the inner side wall of the housing 40 defining each of the throttle portions 47 a, 47 b projects toward an inside of the receive space 41 , and has a circular arc shape in a plan view.
- the inner side walls defining the throttle portions 47 a, 47 b are located symmetrically with respect to the receive space 41 .
- the adhesive member 80 used has such a volume that, when the adhesive member 80 is pushed out by the part of the back surface of the sensor chip 30 on the second end and the surface 44 a of the bonding member 44 , the adhesive member 80 reaches an upper end of each clearance 43 a, 43 b, 43 c, which are adjacent to the covered portion 50 a. That is, when the sensor chip 30 is pressed using a pressing apparatus in a pressing step of manufacturing, a surface of the sensor chip 30 , a surface of the housing 40 , and a surface of the adhesive member 80 in each clearances 43 a, 43 b, 43 c become in the same plane at the boundary part 50 b of the covered portion 50 a (see FIGS. 1B and 1C ).
- the surfaces of the sensor chip 30 , the housing 40 , and the adhesive member 80 in each clearance 43 a, 43 b, 43 c are prevented from forming a step at the boundary part 50 b. Accordingly, when the molded member 50 is formed by injection molding through injecting a molding material toward the covered portion 50 a, it is possible to prevent formation of a clearance between: a lower surface of a mold used in molding; and the surfaces of the sensor chip 30 , the housing 40 , and the adhesive member 80 . As a result, the molding material may not be leaked from the clearance, and the leaked molding material may not be attached to the sensor chip 30 or a surface of the housing 40 . Therefore, a buffer member that is conventionally used is not necessary, and thus, it is possible improve a production yield of the heat type flow amount sensor apparatus 100 . It is also possible to improve production efficiency.
- an adhesive member having a film shape is used as an adhesive member since control of a volume, a size and a shape is easy and since positioning on a bonding area is easy.
- a non-conductive film (NCF) made of epoxy resin may be used as an adhesive member having a film shape since the NCF has a high rate of thermal hardening and an insulating property.
- the NCF has an adhesive layer on a bonding plane, and the adhesive layer is soft under ambient temperatures and becomes hard when temperature reaches a curing temperature.
- a surface of the sensor chip 30 and a surface of the housing 40 are also in the same plane.
- air flowing around the sensing member 32 may not be disordered.
- Heaters 32 a, 32 b are formed on the membrane member 31 of the sensor chip 30 .
- the heater 32 a is located on an upstream side of an air flow, which is shown as the outline arrow “F 1 ” in FIG. 5 .
- the heater 32 b is located on a downstream side of the air flow.
- the membrane member 31 and the pair of heaters 32 a, 32 b are components of the sensing member 32 .
- the sensor chip 30 further includes temperature sensors 37 a, 37 b and a resistive element including wiring layers 33 a to 33 f.
- the temperature sensor 37 a, 37 b senses an ambient temperature of the heat type flow amount sensor apparatus 100 .
- the membrane member 31 is much thinner than the semiconductor substrate 30 a, the membrane member 31 has a small heat capacity, and thermal insulation of the membrane member 31 from the semiconductor substrate 30 a is ensured. Further, since the heaters 32 a, 32 b are formed on the membrane member 31 , the sensing member 32 has a high sensitivity.
- an insulating film is formed on a surface of the silicon substrate.
- the insulating film is, for example, a silicon nitride film or a silicon oxide film.
- a semiconductor layer that is formed through thermal diffusion of impurities in a silicon layer is patterned.
- the heaters 32 a, 32 b, the temperature sensors 37 a, 37 b and the resistive element including the wiring layers 33 a to 33 f are formed.
- an SOI substrate is used to provide the silicon substrate, the insulating film and the semiconductor layer.
- the SOI substrate has a support substrate as the silicon substrate, an buried oxide layer (BOX layer) as the insulating film, and a SOI layer as the semiconductor layer.
- BOX layer buried oxide layer
- the semiconductor layer is covered by an insulating film made of, for example, a boron-doped phospho-silicate glass (BPSG) layer.
- the semiconductor layer is electrically connected with the pads 34 a to 34 f through contact holes formed at predetermined positions of the insulating film.
- the pads 34 a to 34 f are made of, for example, aluminum.
- a silicon nitride film is formed on a surface of the insulating film so as to cover a generally whole of the silicon substrate, thereby to protect a surface of the sensor chip 30 . Openings are formed on the silicon nitride film at positions that respectively correspond to the pads 34 a to 34 f. Through the openings, the pads 34 a to 34 f are connected to the wires 60 by wire bonding, and thereby, the pads 34 a to 34 f are electrically connected with the leads 70 .
- the heaters 32 a, 32 b are driven by a control circuit (not shown) that is electrically connected with the leads 70 .
- the control circuit controls the heaters 32 a, 32 b so that temperatures of the heaters 32 a, 32 b become higher than an ambient temperature by 200 degrees C.
- the ambient temperature is sensed by the temperature sensors 37 a, 37 b. More specifically, an electric current flows from the control circuit to the heater 32 a via the pads 34 b, 34 c and the wiring layers 33 b, 33 c, and an electric current flows from the control circuit to the heater 32 b via the pads 34 d, 34 e and the wiring layers 33 d, 33 e.
- each heater 32 a, 32 b having a predetermined line width is heated, and temperatures of the heaters 32 a, 32 b increase accordingly.
- the heat is radiated from the heaters 32 a, 32 b to an air flow.
- An amount of the heat radiated from the heaters 32 a, 32 b depends on a flow amount of air.
- the control circuit adjusts the electric current so that temperature of the heaters 32 a, 32 b is constant. In the above adjustment, a variation in the electric current is acquired as a signal, and the flow amount of air is calculated based on the signal. Further, depending on a direction of the air flow, there arises a difference between the heat radiated from one of the heaters 32 a, 32 b and that radiated from the other of the heaters 32 a, 32 b.
- the heater 32 a located at the upstream side radiates much more heat and requires much more electric current, compared to the heater 32 b located at the downstream side. Based on this difference, it is possible to sense the direction of the air flow as well as a flow amount of air.
- the temperature sensors 37 a, 37 b are used for sensing an ambient temperature, which is used as a reference.
- the direction of air flow is assumed to be that shown as the outline arrow “F 1 ” in FIG. 5 .
- the control circuit increases electric conduction to the heater 32 a to maintain temperature or resistance of the heater 32 a at a constant value. Since the air heated by the heater 32 a passes over the heater 32 b, the heat radiated from the heater 32 b becomes small, and the control circuit reduces electric conduction to the heater 32 b. Based on an amount of the electric conduction to the heater 32 a and that to the heater 32 b, it becomes possible to detect an flow amount of air and a direction of air flow.
- the heater 32 a, 32 b includes heat generating resistance element, and also functions as a temperature sensitive resistance element. That is, the heater 32 a, 32 b maintains the resistance thereof at a constant value with interaction between the temperature and the resistance of the heater 32 a, 32 b. Thus, if the resistance is changed due to stress in the sensor chip 30 (an effect known as a piezoresistance effect), it becomes difficult to properly maintain the temperature and the piezoresistance effect can be a factor for error.
- the piezoresistance effect is negligible since: the part of the sensor chip 30 on the second end side is bonded and fixed to the housing 40 ; a part other than the bonded portion is exposed in the receive space 41 ; and the exposed part are not in contact with any member. It is therefore possible to detect a flow amount with high accuracy.
- an adhesive member 80 is placed on a surface 44 a of a bonding member 44 of the housing 40 prepared at S 1 , as shown in FIGS. 7A and 7B .
- the adhesive member 80 is placed on the surface 44 a of the bonding member 44 by using, for example, a collet, which is used for placing an IC chip on a printed circuit board.
- An area of the adhesive member 80 is formed smaller than an area of the surface 44 a.
- the adhesive member 80 is placed on the surface 44 a of the bonding member 44 so that the adhesive member 80 and the inner side walls 42 a, 42 b, 42 c of the housing 40 define clearances 46 a, 46 b, 46 c therebetween.
- the adhesive member 80 is placed so that the clearances, which are defined between the adhesive member 80 and the inner side walls 42 a, 42 b, 42 c, have a generally same width.
- the clearances is formed so that the clearances 43 a, 43 b, 43 c will be evenly filled with the adhesive member 80 when the front surface 30 b of the sensor chip 30 is pressed in a later process S 4 .
- the sensor chip 30 is placed on the adhesive member 80 that is placed on the surface 44 a of the bonding member 44 . More specifically, the sensor chip 30 is placed so that a part of the back surface of the sensor chip 30 on a pad ( 34 a to 34 f ) side is bonded to the adhesive member 80 .
- a throttle portion 47 a, 47 b which functions as a positioning portion as described
- a pressing apparatus for pressing the front surface of the sensor chip 30 includes a pressing member 90 .
- the pressing member 90 has a built-in heater 95 , and a flat pressing surface 90 a on a lower surface thereof.
- the pressing surface 90 a is made of a material that the adhesive member 80 is hard to be attached to.
- the pressing member 90 is made of, for example, metal, resin, ceramic or the like.
- a surface of the pressing member corresponding to the pressing surface is coated by Teflon (registered trademark).
- the pressing member may be made of Teflon.
- the front surface 30 b of the sensor chip 30 placed on the bonding member 44 projects from the front surface of the housing 40 .
- the adhesive member 80 is pressed and deformed by the back surface of the sensor chip 30 and the surface 44 a of the bonding member 44 .
- the pushed and deformed adhesive member 80 partially flows into the clearances 43 a, 43 b, 43 c and moves upward in each clearance 43 a, 43 b, 43 c.
- the pressing is stopped when the pressing surface 90 a of the pressing member 90 contacts the front surface 40 a of the housing 40 .
- FIG. 9B is a cross sectional taken along line in a thickness direction of the sensor chip 30 , the line passing through the boundary part 50 b of the covered portion 50 a.
- the following surfaces are in the same plane: the front surface 30 b of the sensor chip 30 ; the front surface 40 a of the housing 40 ; the surface 80 a of the adhesive member 80 that is located in the clearance 43 a; the surface 80 b of the adhesive member 80 that is located in the clearance 43 b; and the surface of the adhesive member 80 that is located in the clearance 43 c. That is, at the boundary part 50 b of the covered portion 50 a, the surfaces of the sensor chip 30 , the housing 40 and the adhesive member 80 are in the same plane and do not have a step.
- the throttle portions 47 a, 47 b restricts the flow toward the sensing member 32 en route to the sensing member 32 .
- a large part of the adhesive member 80 flows in the clearances 43 a, 43 b, 43 c, and reaches an upper end of each clearance 43 a, 43 b, 43 c.
- the adhesive member 80 may spread beyond the throttle portions 47 a, 47 b. In such a case, the adhesive member 80 spreading beyond the throttle portions 47 a, 47 b flows in and are trapped in the relief portions 41 a, 41 b. The adhesive member 80 therefore does not reach the vicinity of the sensing member 32 .
- the adhesive member 80 moving upward in each clearance 43 a, 43 b, 43 c stops to further move upward owing to the presence of the pressing surface 90 a of the pressing member 90 .
- the adhesive member 80 therefore cannot leak to the front surface of the sensor chip 30 and the front surface of the housing 40 .
- the heater 95 Upon finishing the pressing of the sensor chip by using the pressing member 90 , the heater 95 activates in a state where the front surface 30 b of the sensor chip 30 is pressed by the pressing surface 90 a. The heat generated by the heater 95 conducts to the adhesive member 80 via the sensor chip 30 , and causes the adhesive member 80 , which has a thermosetting property, to harden. Since the sensor chip 30 is formed using the silicon substrate having a high thermal conductivity, the adhesive member 80 hardens in a moment.
- each pad 34 a to 34 f of the sensor chip 30 is electrically connected to a corresponding one of the leads 70 .
- the electrical connection between the each pad 34 a to 34 f and the corresponding lead 70 is made using the wire 60 by wire bonding, as shown in FIGS. 10A and 10B .
- the pads 34 a to 34 f may be electrically connected with a printed circuit board instead of the lead 70 , depending on an external element to which the heat type flow amount sensor apparatus is to be connected. In such a case, by ultrasonic welding, the pads 34 a to 34 f may be electrically connected to the printed circuit board with stud bumps.
- a portion 94 a (referred to hereinafter as a film cover portion) including the boundary part 50 b of the covered portion 50 a is covered with a film 94 made of synthetic resin, as shown in FIGS. 10A and 10B .
- the members formed through S 1 to S 6 are placed in a mold space 93 (space for forming the molded member 50 by injection molding through injecting a molding material) defined by a lower part 92 of a mold. Then, as shown in FIG. 11B , an upper part 91 of the mold is connected to the lower part 92 of the mold to close the mold.
- a lower surface 91 a of the upper part 91 of the mold has a part that corresponds to the covered portion 50 a and that defines the mold space 93 .
- the other part of the lower surface 91 a of the upper part 91 contacts a part of the front surface 40 a of the housing 40 and a part of the front surface 30 b of the sensor chip 30 , wherein the part of the front surface 30 b and the part of the front surface 40 a extends from the boundary part 50 b to the film covered portion 94 a.
- an upper surface 92 a of the lower part 92 of the mold has a part that corresponds to the covered portion 50 a and that defines the mold space 93 .
- the other part of the upper surface 92 a contacts a part of the back surface of the housing 40 and a part of the back surface of the sensor chip 30 , wherein the parts of the back surfaces of the housing 40 corresponds to the other part of the lower surface 91 a of the upper part 91 of the mold.
- a molding material is injected into the mold space 93 to fill the mold space 93 with the molding material.
- the front surface of the sensor chip 30 , the front surface of the housing 40 , and a surface of the adhesive member 80 reaching an upper end of the clearance 43 a, 43 b are in the same plane at the boundary part 50 b of the covered portion 50 a, as shown in FIG. 9B .
- a gap is not formed between the lower surface 91 a of the upper part 91 of the mold and the above-described surfaces being in the same plane.
- the injected molding material cannot spread and cannot leak to the front surface 40 a of the housing 40 beyond the boundary part 50 b.
- the side surfaces 36 a, 36 b have irregularities resulting from, for example, a process of forming the sensor chip 30 by dicing a semiconductor substrate.
- the irregularities are filled with the adhesive member 80 , the molding material cannot leak out via the irregularities. This commonly happens when the inner side walls 42 a, 42 b of the housing 40 have irregularities.
- the front surface 40 a of the housing 40 has a flaw in a concave shape at a part crossing the boundary part 50 b.
- the film 94 covers the flaw 40 b, as shown in FIG. 12B .
- a pressure applied when the mold is closed presses and deforms the film located between the lower surface 91 a of the upper part 91 of the mold and the front surface 40 a of the housing, and then, the flaw 40 b is filled with the film 94 , as shown in FIG. 12C .
- the molding material injected into the mold space 93 at S 8 cannot spread and cannot reach the front surface 30 b of the sensor chip 30 and the front surface 40 a of the housing 40 beyond the boundary part 50 b.
- the flow is filled with the film 94 , and thus, the molding material cannot leak out via the flaw.
- a surface 80 a or a surface 80 b (see FIG. 9B ) of the adhesive member 80 has a flaw at a portion extending across the boundary part 50 b, the flaw is also filled with the film 94 , and thus, the molding material cannot leak out via the flaw.
- the step is covered with the film 94 , and thus, the molding material cannot leak out via the step.
- the lower surface 91 a of the upper part 91 of the mold has a flaw at a portion extending across the boundary part 50 b, the flaw is filled with the film 94 , and thus, the molding material cannot leak out via the flaw.
- the foreign element When another factor other then the flaw in a concave shape, such as a foreign element having a convex shape, exists at the boundary part 50 b, the foreign element is absorbed or covered by the film 94 and does not form a gap, and thus, the foreign element cannot be a factor for leaking the molding material.
- a surface of the mold corresponding to the mold space 93 is cooled, and the molding material filling in the mold space 93 hardens. Then, at S 10 , the upper part 91 of the mold is moved upward to open the mold. At S 11 , the heat type flow amount sensor apparatus 100 is removed from the mold space 93 , as shown in FIG. 11D .
- a gap is not formed at the boundary part 50 b of the covered portion 50 a when the covered portion 50 a is formed using the molding material by injection molding, and thus, the molding material cannot leak to a region other than the covered portion. It is possible to prevent leak of the molding material without using a buffering member, which is used in a conventional manner. Thus, it is possible to improve a production yield and production efficiency of a heat type flow amount sensor apparatus.
- a position, a shape and a size of the relief portion, and the number of relief portions can be changed as long as the pushed out adhesive member cannot reach the vicinity of the sensing member 32 .
- the inner side wall 42 c of the housing 40 located on a pad 34 side may defines relief portions 43 g arranged at predetermined intervals each.
- Each relief portion 43 g has a ditch shape and is in communication with the clearance 43 c and extends in a direction away from the sensing member 32 .
- the inner side wall 42 c of the housing 40 on a pad 34 side may defines relief portions 43 h each formed in a circular arc shape in a plan view. According to the above structure, it is possible to provide an advantage generally identical to that of the first modification.
- the inner side wall 42 a of the housing 40 defining the clearance 43 a may further defines multiple relief portions 43 i each having a ditch shape and each extending outwardly. Further, the inner side wall 42 b of the housing 40 defining the clearance 43 b may further defines multiple relief portions 43 i each having a ditch shape and each extending outwardly. According to the above structure, it is possible to provide an advantage generally identical to that of the first modification.
- the inner side wall 42 a of the housing 40 defining the clearance 43 a may further defines multiple relief portions 43 j each having a circular arc shape in a plan view and each extending outwardly.
- the inner side wall 42 b of the housing 40 defining the clearance 43 b may further defines multiple relief portions 43 i each having a circular arc shape in a plan view each extending outwardly.
- FIG. 17A is a cross sectional diagram illustrating the adhesive member prior to pressing in accordance with a fifth modification.
- FIG. 17B is a cross sectional diagram illustrating the adhesive member after the pressing in accordance with the fifth modification.
- both end parts of the adhesive member 80 respectively reach the inner side walls 42 a, 42 b of the housing 40 .
- other adhesive members 81 thinner than the adhesive member 80 are respectively located on surfaces of both end parts of the adhesive member 80 .
- the adhesive members 81 are respectively formed in sizes so that, when the sensor chip 30 is placed on the adhesive member 80 , the adhesive members 81 can placed in clearances 43 a, 43 b between the side surfaces of the sensor chip 30 and the inner side walls 42 a, 42 b of the housing 40 .
- a thickness given by the adhesive members 80 , 81 becomes larger than a thickness of the adhesive member 80 located on the back surface of the sensor chip 30 .
- the front surface 30 b of the sensor chip 30 is pressed by the pressing surface 90 a of the pressing member 90 , and then, the adhesive member 80 is pressed and deformed, and the pressed adhesive member 80 partially flows in the clearances 43 a, 43 b. Thereby, each adhesive member 81 moves upward until contacting the pressing surface 90 a, and the clearances 43 a, 43 b are filled.
- the adhesive members 80 , 81 may be integrated in advance and may be placed on the bonding member. In such a case, it is possible to reduce a process of placing the adhesive member one time.
- an adhesive member having a concave shape in a longitudinal cross sectional view may be employed, and the sensor chip 30 may be placed on a bottom of the concave shape of the adhesive member.
- the adhesive member may be placed on a part of the back surface of the sensor chip 30 that corresponds to the surface 44 a of the bonding member 44 , and the sensor chip 30 may be placed on the surface 44 a of the bonding member 44 .
- the housing 40 that defines the receive space having a closed bottom may be used, and the part of the sensor chip 30 on the second end side may be bonded to a part of the bottom of the receive space on the second end side.
- the throttle portions may be formed on each of three or four inner side walls of the housing 40 . In such a case, it becomes possible to more easily position the sensor chip 30 , and possible to improve the positioning accuracy.
- the above embodiments can be applied to not only a heat flow amount sensor apparatus but various sensor apparatuses in which a sensing member is exposed.
- the various sensor apparatuses include a pressure sensor apparatus, a humidity sensor apparatus, a solar radiation sensor apparatus, an infrared sensor apparatus and the like.
- a method of manufacturing a sensor apparatus includes: preparing a sensor chip 30 including a substrate 30 a, a sensing member 32 located on the substrate 30 a, and a terminal 34 a to 34 f located on the substrate 30 a and configured to output a signal from the sensing member 32 ; and preparing a housing 40 .
- the housing 40 has (i) a first opening 45 a on a front surface thereof, (ii) an inner side wall 42 a to 42 d defining a receive space 41 therein communicating with the first opening 45 a, and (iii) a bonding member 44 located on an inner bottom surface of the housing 40 at a boundary part 50 b of a predetermined portion 50 a.
- the inner bottom surface defines a bottom of the receive space 41 .
- a depth D 2 defined between the first opening 45 a and the bonding member 44 is deeper compared to a thickness D 1 of the sensor chip 30 .
- the method further includes: placing an adhesive member 80 on one of the bonding member 44 and a back surface of the sensor chip 30 ; and placing the sensor chip 30 in the receive space 41 through the first opening 45 a so that the sensing member 32 is exposed.
- the placing of the sensor chip 30 includes placing the back surface of the sensor chip 30 on the bonding member 44 via the adhesive member 80 to form a clearance 43 between a side surface 36 a to 36 d of the sensor chip 30 and the inner side wall 42 a to 42 d of the housing 40 .
- the method further includes: pressing the front surface of the sensor chip 30 whose back surface is placed on the bonding member 44 , so that: the sensor chip 30 and the housing 40 push the adhesive member 80 to the clearance 43 ; and the front surface of the sensor chip 30 , the front surface of the housing 40 and a surface of a part of the adhesive member 80 pushed in the clearance 43 are in a same plane at the boundary part 50 b.
- the method further includes: electrically connecting the terminal 34 a to 34 f to an electrical conductive member 60 , the electrical conductive member 60 to be electrically connected to an external element 70 ; and forming, by injection molding, a molded member 50 that covers the predetermined portion 50 a including a connection part where the terminal 34 a to 34 f and the electric conductive member 60 are connected with each other.
- the forming of the molded member 50 includes: closing a mold receiving the sensor chip 30 , the housing 40 and the electric conductive member 60 , after the pressing of the front surface of the sensor chip 30 and the electrically connecting of the terminal 34 a to 34 f; and injecting a molding material in the mold.
- a sensor apparatus includes: a sensor chip 30 including a substrate 30 a, a sensing member 32 located on the substrate 30 a, and a terminal 34 a to 34 f located on the substrate 30 a and configured to output a signal from the sensing member 32 ; a housing 40 receiving the sensor chip 30 with the sensing member 32 of the sensor chip 30 being exposed; an electric conductive member 60 electrically connected with the terminal 34 a to 34 f and to be electrically connected with an external element 70 ; and a molded member 50 covering a covered portion 50 a including a connection portion where the terminal 34 a to 34 f and the electric conductive member 60 are connected with each other.
- the housing 40 has a first opening 45 a on a front surface thereof.
- the housing 40 defines a receive space 41 therein (i) communicating with the first opening 45 a and (ii) receiving the sensor chip 30 through the first opening 45 a while the housing 40 and a side surface 36 a to 36 d of the sensor chip 30 define a clearance 43 therebetween.
- the housing 40 further has a bonding member 44 .
- the bonding member 44 is located on an inner bottom surface of the housing 40 at a place corresponding to a boundary part 50 b of the covered portion 50 a, the inner bottom surface defining a bottom of the receive space 41 .
- the bonding member 44 is bonded to a back surface of the sensor chip 30 via an adhesive member 80 .
- the first opening 45 a and the bonding member 44 define therebetween a depth D 2 , the depth D 2 being deeper compared to a thickness D 1 of the sensor chip 30 .
- a part of the adhesive member 80 is located in the clearance 43 by being pressed and pushed out by the sensor chip 30 and the housing 40 .
- the front surface of the housing 40 , a surface of the part of the adhesive member 80 , and a front surface of the sensor chip 30 are in a same plane at the boundary part 50 b.
- the adhesive member placed between the back surface of the sensor chip and the bonding member is partially pushed out and flows in the clearance between the side surface of the sensor chip and the inner side wall of the housing. Then, the surface of the part of the adhesive member flowing in the clearance, the front surface of the sensor chip, and the front surface of the housing are in the same plane at the boundary part of the covered portion (i.e., predetermined portion).
- a gap is not formed between the mold and the above surfaces, and thus, the molding material cannot leak a region other than the covered portion (i.e., a predetermined portion).
- a buffer member which is used in a conventional manner. It is possible to improve a production yield of the sensor apparatus. Further, it is possible to improve production efficiency of the sensor apparatus.
- a method of manufacturing a sensor apparatus includes: preparing a sensor chip 30 including a substrate 30 a, a sensing member 32 located on the substrate 30 a, and a terminal 34 a to 34 f located on the substrate 30 a and configured to output a signal from the sensing member 32 ; and preparing a housing 40 .
- the housing 40 has (i) a first opening 45 a on a front surface of the housing 40 , (ii) an inner side wall 42 a to 42 d defining a receive space 41 therein communicating with the first opening 45 a, and (iii) a bonding member 44 located on an inner bottom surface of the housing 40 at a boundary part 50 b of a predetermined portion 50 a.
- the inner bottom surface defines a bottom of the receive space 41 .
- a depth D 2 defined between the first opening 45 a and the bonding member 44 is deeper compared to a thickness D 1 of the sensor chip 30 .
- the method further includes: placing an adhesive member 80 on one of the bonding member 44 and a back surface of the sensor chip 30 ; placing the sensor chip 30 in the receive space 41 through the first opening 45 a so that the sensing member 32 is exposed.
- the placing of the sensor chip 30 includes placing the back surface of the sensor chip 30 on the bonding member 44 via the adhesive member 80 to form a clearance 43 between a side surface 36 a to 36 d of the sensor chip 30 and the inner side wall 42 a to 42 d of the housing 40 .
- the method further includes: pressing the front surface of the sensor chip 30 whose back surface is placed on the bonding member 44 , so that the sensor chip 30 and the housing 40 push the adhesive member 80 to the clearance 43 ; electrically connecting the terminal 34 a to 34 f to an electrical conductive member 60 , the electrical conductive member 60 to be electrically connected to an external element 70 ; placing a film 94 on the front surface of the sensor chip 30 and the front surface of the housing 40 so that the film 94 covers the boundary part 50 b of the predetermined portion 50 a, after the pressing of the front surface of the sensor chip 30 and the electrically connecting of the terminal 34 a to 34 f; and forming, by injection molding, a molded member 50 that covers the predetermined portion 50 a including a connection part where the terminal 34 a to 34 f and the electric conductive member 60 are connected with each other.
- the forming of the molded member 50 includes: closing a mold receiving the sensor chip 30 , the housing 40 and the electric conductive member 60 , after the pressing of the front surface of the sensor chip 30 and the electrically connecting of the terminal 34 a to 34 f; and injecting a molding material in the mold.
- the mold is closed in a state where the film is formed on the front surface of the sensor chip and the front surface of the housing so as to cover the boundary part.
- the irregularities are filled with the film owing to pressure of the closing of the mold, and as a result, the gap disappears.
- a gap between the mold and the above surfaces does not exist there is not.
- the molding material cannot leak a region other than the covered portion (i.e., a predetermined portion). It is possible to prevent the leak of the molding material without using a buffer member, which is used in a conventional manner. It is possible to improve a production yield of the sensor apparatus. Further, it is possible to improve production efficiency of the sensor apparatus.
- the irregularities can be filled with the film. Therefore, the molding material cannot the leak via the step.
- the manufacturing method according to the third aspect may further have the following feature.
- the film 94 is placed so as to cover: the boundary part 50 b; the sensing member 32 ; a part of the sensor chip 30 between the boundary part 50 b and the sensing member 32 ; and the front surface of the housing 40 .
- the film can function as a buffer member to protect a surface of the sensor chip and a surface of the housing from damage due to contact with the mold in the closing the mold.
- the manufacturing method according to the first or third aspect may further have the following feature.
- the inner side wall 42 a, 42 b of the housing 40 defines an in-flow portion 41 a, 41 b having a capacity for receiving the part of the adhesive member 80 pushed to the clearance 43 .
- the sensor apparatus may further has the following feature.
- the housing 40 has an inner side wall 42 a to 42 d defining the clearance 43 , and the inner side wall 42 a, 42 b of the housing 40 further defines an in-flow portion 41 a, 41 b having a capacity for receiving the part of the adhesive member 80 pushed out to the clearance 43 .
- the in-flow portion is formed on the inner side wall, which defines the clearance, of the housing.
- the adhesive member pushed to the clearance can flow into the in-flow portion.
- the above adhesive member 80 may have a volume such that the part of the adhesive member 80 pushed to the clearance 43 flows in the in-flow portion 41 a, 41 b when the front surface of the sensor chip 30 is pressed.
- the surface of the adhesive member filling the clearance may be positioned lower than the surface of the sensor chip and the surface of the housing, owing to shortage of the adhesive member.
- a volume of the adhesive member is set such that: the part of the adhesive member 80 pushed to the clearance 43 flows in the in-flow portion 41 a, 41 b when the front surface of the sensor chip 30 is pressed.
- the volume of the adhesive member is set such that the, even if the adhesive member fills the clearance at the boundary part, the adhesive member still has an extra part that is to flow into the in-flow part. Therefore, it is not necessary to control a size of the sensor chip and a size of the housing with high accuracy. It is possible to further improve a production yield of the sensor apparatus. Further, it is possible to further improve production efficiency of the sensor apparatus.
- the manufacturing method according to the first aspect or the third aspect may further have the following features.
- the side surface 36 a to 36 d of the sensor chip 30 includes a first side surface 36 a, a second side surface 36 b and a third side surface 36 c.
- the first and second side surfaces 36 a, 36 b are opposite to each other, and are continuously connected to a first end and a second end of the third side surface 36 c, respectively.
- the third side surface 36 c is located on a terminal 34 a to 34 f side.
- the inner side wall 42 a to 42 d of the housing 40 includes a first inner side wall 42 a facing the first side surface 36 a of the sensor chip 30 and a second inner side wall 42 b facing the second side surface 36 b of the sensor chip 30 .
- the first side surface 36 a of the sensor chip 30 and the first inner side wall 42 a of the housing 40 define therebetween a first clearance 43 included in the clearance 43 .
- the second side surface 36 b of the sensor chip 30 and the second inner side wall 42 b of the housing 40 define therebetween a second clearance 43 included in the clearance 43 .
- the first inner side wall 42 a and the second inner side wall 42 b of the housing 40 respectively define a first in-flow portion 41 a and a second in-flow portion 41 b included in the in-flow portion.
- the sensor apparatus may further have the following features.
- the side surface 36 a to 36 d of the sensor chip 30 includes a first side surface 36 a, a second side surface 36 b and a third side surface 36 c.
- the first and second side surfaces 36 a, 36 b are opposite to each other, and are continuously connected to a first end and a second end of the third side surface 36 c, respectively.
- the third side surface 36 c is located on a terminal 34 a to 34 f side.
- the inner side wall 42 a to 42 d of the housing 40 includes a first inner side wall 42 a facing the first side surface 36 a of the sensor chip 30 and a second inner side wall 42 b facing the second side surface 36 b of the sensor chip 30 .
- the first side surface 36 a of the sensor chip 30 and the first inner side wall 42 a of the housing 40 define therebetween a first clearance 43 included in the clearance 43 .
- the second side surface 36 b of the sensor chip 30 and the second inner side wall 42 b of the housing 40 define therebetween a second clearance 43 included in the clearance 43 .
- the first inner side wall 42 a and the second inner side wall 42 b of the housing 40 respectively define a first in-flow portion 41 a and a second in-flow portion 41 b included in the in-flow portion.
- the clearance includes the first and second clearances
- the adhesive member pushed by the sensor chip and the bonding member flows along the first and second side surfaces of the sensor chip.
- the first and second in-flow portions are respectively formed on the first and second inner side walls of the housing, the adhesive member flowing along the first and second side surfaces of the sensor chip can flow into the first and second in-flow portions, respectively.
- the above manufacturing method according to the third aspect may further have the following features.
- the inner side wall 42 a to 42 d of the housing 40 includes a third inner side wall 42 c facing the third side surface 36 c of the sensor chip 30 .
- the third side surface 36 c of the sensor chip 30 and the third inner side wall 42 c of the housing 40 define therebetween a third clearance 43 included in the clearance 43 .
- the third inner side wall 42 c defines a third in-flow portion 41 a, 41 b included in the in-flow portion.
- the above sensor apparatus may further have the following features.
- the inner side wall 42 a to 42 d of the housing 40 includes a third inner side wall 42 c facing the third side surface 36 c of the sensor chip 30 .
- the third side surface 36 c of the sensor chip 30 and the third inner side wall 42 c of the housing 40 define therebetween a third clearance 43 included in the clearance 43 .
- the third inner side wall 42 c defines a third in-flow portion 41 a, 41 b included in the in-flow portion.
- the adhesive member flowing in the third clearance can further flow into the third clearance.
- the above manufacturing method according to the third aspect or the above sensor apparatus according to the second aspect may alternatively have the following features.
- the inner side wall 42 a to 42 d of the housing 40 includes a third inner side wall 42 c facing the third side surface 36 c of the sensor chip 30 ; the third side surface 36 c of the sensor chip 30 and the third inner side wall 42 c of the housing 40 define therebetween a third clearance 43 included in the clearance 43 .
- the third inner side wall 42 c does not define the in-flow portion 41 a, 41 b.
- the in-flow portion since the in-flow portion is not formed on the third inner side wall of the housing, the in-flow portion cannot be an obstacle for electrical connection of the terminal to the electric conductive member.
- the manufacturing method according to the first or third aspect and the sensor apparatus according to the second aspect may further have the following features.
- the sensing member 32 of the sensor chip 30 outputs a signal that depends on a flow amount of air.
- the pressing of the front surface of the sensor chip 30 includes causing the front surface of the sensor chip 30 and the front surface of the housing 40 to be in the same plane.
- the sensing member When the sensing member is used for outputting a signal that depends on a flow amount of air, it is desirable that the air flowing around the sensing member be not disordered.
- the pressing the sensor chip since the pressing the sensor chip causes the front surface of the sensor chip and the front surface of the housing to be in the same plane, the front surface of the sensor chip and the front surface of the housing does not form a gap, which can be a factor for disordering the air flowing around the sensing member.
- the method according to the first or third aspect may further have the following features.
- the inner side wall 42 a to 42 d of the housing 40 defines a positioning portion 47 a, 47 b for positioning the sensor chip 30 in the receive space 41 of the housing 40 .
- the sensor chip 30 is positioned with reference to the positioning portion 47 a, 47 b.
- the sensor apparatus may have the following features.
- the inner side wall 42 a to 42 d of the housing 40 defines a positioning portion 47 a, 47 b for use in positioning the sensor chip 30 in the receive space 41 of the housing 40 .
- the above manufacturing method and the above sensor apparatus may further have the following features.
- the inner side wall 42 a to 42 d of the housing 40 defines, at a region between the boundary part 50 b and the in-flow portion, a throttle portion 47 a, 47 b that restricts a flow of the part of the adhesive member 80 in the clearance 43 .
- the adhesive member since it is possible to restrict the flowing of the adhesive member in the clearance toward the in-flow portion, the adhesive member can readily flow in the clearance toward the surface. Therefore, at the boundary part, the adhesive member can be filled with the clearance and can reach the upper end of the clearance reliably, and thus, it is possible to eliminate a gap at the boundary part.
- the above manufacturing method may further have the following features.
- the throttle portion 47 a, 47 b provides the positioning portion 47 a, 47 b.
- the sensor chip 30 is positioned with reference to the positioning part.
- the above sensor apparatus may further have the following feature: the throttle portion 47 a, 47 b provides the positioning portion 47 a, 47 b.
- the throttle portion 47 a, 47 b can function as the positioning portion 47 a, 47 b, it is necessary to form the throttle portion 47 a, 47 b and the positioning portion 47 a, 47 b separately. It is possible to further improve production efficiency of the sensor apparatus.
- the manufacturing method according to the first and third aspects, and the sensor apparatus according to the second aspect may further have the following features.
- the back surface of the sensor chip 30 has a first part at an end of the sensor chip 30 , the first part corresponding to the boundary part 50 b.
- the first part of the back surface is bonded to the bonding member 44 of the housing 40 .
- Another part of the back surface of the sensor chip 30 other than the first part is spaced apart from the bottom of the receive space 41 .
- the first part of the back surface of the sensor chip is bonded to the bonding member, and a part of the sensor chip other than the first part is spaced apart of the bottom of the receive space. It is thus possible reduce a bonded area of the sensor chip. Therefore, even if the sensor chip and the housing are made of materials having different coefficients of thermal expansion, it becomes possible to reduce thermal stress acting on the sensor chip, and thus, it is possible to prevent generation of warpage, strain or crack in the sensor chip.
- the sensing member is one that detects a flow amount of air
- the sensor chip is configured such that an electric path for electrically connecting the sensing member and an external control circuit is formed on the sensor chip, a piezoresistive effect resulting from the warpage or strain in the sensor chip may cause a change of an electric signal traveling on the electric path and may reduce the detection accuracy.
- the manufacturing method according to the first and third aspects, and the sensor apparatus according to the second aspect may further have the following feature: the inner bottom surface of the housing 40 has a second opening at a region other than the bonding member 44 .
- the manufacturing method according to the first aspect and the third aspect may further have the following features.
- the adhesive member 80 includes a thermosetting adhesive member 80 .
- the pressing of the front surface of the sensor chip 30 includes: heating the adhesive member to harden the adhesive member.
- the sensor apparatus according to the second aspect may further has the following features.
- the adhesive member 80 includes a thermosetting adhesive member 80 .
- the manufacturing method according to the first aspect and the third aspect and the sensor apparatus according to the second aspect may further have the following feature: the adhesive member 80 has a film shape.
- the adhesive member since the adhesive member has a film shape, the adhesive member is easy to deal and easy to be placed on the back surface of the sensor chip or the bonding member.
- the manufacturing method according to the first aspect and the third aspect may further have the following feature: the substrate 30 a includes a silicon substrate 30 a.
- the substrate since the substrate includes the silicon substrate, it is possible to form and process an insulating layer and a conductive layer with ease. Further, since the silicon substrate has a high thermal conductivity, it is possible to harden the thermosetting adhesive member at a moment by heating the surface of the silicon substrate.
- the manufacturing method according to the first aspect and the third aspect may further have the following aspect: in the pressing of the front surface of the sensor chip 30 , a pressing surface 90 a of a pressing member 90 presses the front surface of the sensor chip 30 , the pressing surface 90 a having an resistance to attachment of the adhesive member 80 thereto.
- the font surface of the sensor chip is pressured by the pressing member having the pressing surface with the resistance to attachment of the adhesive member, it is possible to prevent the adhesive member from attaching to the pressing surface. Further, it is possible to prevent the housing from attaching the pressing member via the adhesive member.
- the pressing surface 90 a may be a planer surface.
- the following area be in the same plane: a surface of the adhesive member that projects from the clearance at the boundary part of the predetermined portion; the front surface of the sensor chip; and the front surface of the housing.
- the sensing member is one that detects a flow amount of air
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Abstract
Description
- The present application is based on Japanese Patent Applications No. 2008-30319 filed on Feb. 12, 2008, the disclosure of which is incorporated herein by reference.
- 1. Field of the Invention
- The present invention relates to a sensor apparatus including an insulating material that covers a terminal for outputting a signal from an exposed sensing member to an external element. The present invention also relate to a method of manufacturing such a sensor apparatus.
- 2. Description of Related Art
- JP-A-2007-33411 corresponding to US Patent Application Publication No. 2007/0022808 proposes a method of manufacturing such a senor apparatuses that includes an insulating material that covers a terminal for outputting a signal from an exposed sensing member to an external element. According to JP-A-2007-33411, a sensor apparatus is manufactured through: attaching a buffer member made of rubber to a boundary part of a region where a molded member is to cover; deforming the buffering member in closing a mold; and filling a ditch between a sensor chip and a support member to prevent a molding material from leaking toward a sensing member in injection molding.
- According to the above method, however, since the buffer member is so tiny, the buffer member and a part to which the buffer member is attached are required to have high dimensional accuracy, and thus, it is difficult to improve a production yield of the sensor apparatus. Further, since the buffer member is required to be attached with high accuracy, it is difficult to improve production efficiency of the sensor apparatus.
- In view of the above and other difficulties, it is an objective of the present invention to provide a sensor apparatus enabling production yield improvement, and to provide a manufacturing method of such a sensor apparatus. It is also an objective of the present invention to provide a sensor apparatus enabling production efficiency improvement, and to provide a manufacturing method of such a sensor apparatus.
- According to a first aspect of the present invention, a method of manufacturing a sensor apparatus is provided. The method includes: preparing a sensor chip including a substrate, a sensing member located on the substrate and a terminal located on the substrate, the terminal outputting a signal from the sensing member; and preparing a housing having (i) a first opening on a front surface thereof, (ii) an inner side wall defining a receive space therein communicating with the first opening, and (iii) a bonding member located on an inner bottom surface of the housing at a boundary part of a predetermined portion. The inner bottom surface defines a bottom of the receive space, and a depth defined between the first opening and the bonding member is deeper compared to a thickness of the sensor chip. The method further includes: placing an adhesive member on one of the bonding member and a back surface of the sensor chip; and placing the sensor chip in the receive space through the first opening so that the sensing member is exposed. The placing of the sensor chip includes placing the back surface of the sensor chip on the bonding member via the adhesive member to form a clearance between a side surface of the sensor chip and the inner side wall of the housing. The method further includes pressing the front surface of the sensor chip whose back surface is placed on the bonding member, so that: the sensor chip and the housing push the adhesive member to the clearance; and the front surface of the sensor chip, the front surface of the housing and a surface of a part of the adhesive member pushed in the clearance are in a same plane at the boundary part. The method further includes: electrically connecting the terminal to an electrical conductive member, the electrical conductive member to be electrically connected to an external element; and forming, by injection molding, a molded member that covers the predetermined portion including a connection part where the terminal and the electric conductive member are connected with each other. The forming of the molded member includes: closing a mold receiving the sensor chip, the housing and the electric conductive member, after the pressing of the front surface of the sensor chip and the electrically connecting of the terminal; and injecting a molding material in the mold.
- According to the above method, in the forming of the molded member covering the predetermined portion by injection molding, there is not a gap, at the boundary part of the predetermined portion, between: the mold; and the front surface of the sensor chip, the surface of the part of the adhesive member and the front surface of the housing. Thus, it is possible to prevent the molding material from leaking to an outside of the predetermined portion. Accordingly, it is possible to improve a production yield and production efficiency of the senor apparatus.
- According to a first aspect of the present invention, a method of manufacturing a sensor apparatus is provided. The method includes: preparing a sensor chip including a substrate, a sensing member located on the substrate and a terminal located on the substrate, the terminal outputting a signal from the sensing member; preparing a housing having (i) a first opening on a front surface of the housing, (ii) an inner side wall defining a receive space therein communicating with the first opening, and (iii) a bonding member located on an inner bottom surface of the housing at a boundary part of a predetermined portion. The inner bottom surface defines a bottom of the receive space, and a depth defined between the first opening and the bonding member is deeper compared to a thickness of the sensor chip. The method further includes: placing an adhesive member on one of the bonding member and a back surface of the sensor chip; and placing the sensor chip in the receive space through the first opening so that the sensing member is exposed. The placing of the sensor chip includes: placing the back surface of the sensor chip on the bonding member via the adhesive member to form a clearance between a side surface of the sensor chip and the inner side wall of the housing. The method further includes: pressing the front surface of the sensor chip whose back surface is placed on the bonding member, so that the sensor chip and the housing push the adhesive member to the clearance; electrically connecting the terminal to an electrical conductive member, the electrical conductive member to be electrically connected to an external element; placing a film on the front surface of the sensor chip and the front surface of the housing so that the film covers the boundary part of the predetermined portion, after the pressing of the front surface of the sensor chip and the electrically connecting of the terminal; and forming, by injection molding, a molded member that covers the predetermined portion including a connection part where the terminal and the electric conductive member are connected with each other. The forming of the molded member includes: closing a mold receiving the sensor chip, the housing and the electric conductive member, after the pressing of the front surface of the sensor chip and the electrically connecting of the terminal; and injecting a molding material in the mold.
- According to the above method, even if the front surface of the sensor chip or the front surface of the housing has irregularities at the boundary part, the irregularities is filled with the film. Therefore, in the forming of the molded member covering the predetermined portion by injection molding, there is not a gap, at the boundary part of the predetermined portion, between: the mold; and the front surface of the sensor chip, the surface of the part of the adhesive member and the front surface of the housing. Thus, it is possible to prevent the molding material from leaking to an outside of the predetermined portion. Accordingly, it is possible to improve a production yield and production efficiency of the senor apparatus.
- According to a third aspect of the present invention, a sensor apparatus is provided. The sensor apparatus includes a sensor chip, a housing, an electric conductive member and a molded member. The sensor chip includes a substrate, a sensing member located on the substrate, and a terminal located on the substrate. The housing receives the sensor chip with the sensing member of the sensor chip being exposed. The electric conductive member is electrically connected with the terminal and to be electrically connected with an external element. The molded member covering a covered portion includes a connection portion where the terminal and the electric conductive member are connected with each other. The housing has a first opening on a front surface thereof. The housing defines a receive space therein (i) communicating with the first opening and (ii) receiving the sensor chip through the first opening while the housing and a side surface of the sensor chip define a clearance therebetween. The housing further has a bonding member. The bonding member is located on an inner bottom surface of the housing at a place corresponding to a boundary part of the covered portion, the inner bottom surface defining a bottom of the receive space. The bonding member is bonded to a back surface of the sensor chip via an adhesive member. The first opening and the bonding member define therebetween a depth, the depth being deeper compared to a thickness of the sensor chip. A part of the adhesive member is located in the clearance by being pressed and pushed out by the sensor chip and the housing. The front surface of the housing, a surface of the part of the adhesive member, and a front surface of the sensor chip are in a same plane at the boundary part.
- According to the above sensor apparatus, in the forming of the molded member covering the covered portion by injection molding, there is not a gap, at the boundary part of the covered portion, between: a mold; and the front surface of the sensor chip, the surface of the part of the adhesive member and the front surface of the housing. Thus, it is possible to prevent a molding material from leaking to an outside of the covered portion. Accordingly, it is possible to improve a production yield and production efficiency of the senor apparatus.
- The above and other objects, features and advantages of the present invention will become more apparent from the following detailed description made with reference to the accompanying drawings. In the drawings:
-
FIG. 1A is a plan view diagram illustrating a heat type flow amount sensor apparatus in accordance with an exemplary embodiment; -
FIG. 1B is a cross sectional diagram taken along line IB-IB ofFIG. 1A ; -
FIG. 1C is a cross sectional diagram taken along line IC-IC ofFIG. 1A ; -
FIG. 2A is a plan view diagram illustrating a sensor chip of a heat type flow amount sensor apparatus exemplified inFIG. 1A ; -
FIG. 2B is a cross sectional diagram taken along line IIB-IIB ofFIG. 2A ; -
FIG. 3A is a plan view diagram illustrating a housing of a heat type flow amount sensor apparatus exemplified inFIG. 1A ; -
FIG. 3B is a cross sectional diagram taken along line IIIB-IIIB ofFIG. 3A ; -
FIG. 4 is a plan view diagram illustrating a sensor chip and a housing which define a clearance therebetween; -
FIG. 5 is a plan view diagram illustrating a sensor chip. -
FIG. 6 is a process chart illustrating a manufacturing flow; -
FIG. 7A is a plan view diagram corresponding to S3 inFIG. 6 and illustrating a housing in which an adhesive member is placed; -
FIG. 7B is a cross sectional diagram taken along line VIIB-VIIB inFIG. 7A ; -
FIG. 8A is a plan view diagram corresponding to S3 and S4 inFIG. 6 and illustrating the pressing of a sensor chip by a pressing member; -
FIG. 8B is a cross sectional diagram taken along line VIIIB-VIIIB inFIG. 8A ; -
FIG. 9A is a plan view diagram corresponding to S4 inFIG. 6 and illustrating a state where a sensor chip is pressed by a pressing member; - FIG, 9B is a cross sectional diagram taken along line IXB-IXB in
FIG. 9A ; -
FIG. 10A is a plan view diagram corresponding to S5 inFIG. 6 and illustrating a state where a lead is connected to a sensor chip by wiring; -
FIG. 10B is a cross sectional diagram taken along line XB-XB inFIG. 10A ; -
FIGS. 11A and 11B are cross sectional diagrams each corresponding to S7 inFIG. 6 ; -
FIG. 11C is a cross sectional diagram corresponding to S8 inFIG. 6 ; -
FIG. 11D is a cross sectional diagram illustrating a heat type flow amount sensor apparatus manufactured; -
FIG. 12A is a cross sectional diagram illustrating a surface flaw formed on a housing; -
FIG. 12B is a cross sectional diagram illustrating a film placed on a housing; -
FIG. 12C is a cross sectional diagram illustrating a state where a surface flaw is filled with a film; -
FIG. 13A is a plan view diagram illustrating a relief portion in accordance with a first modification of the exemplary embodiment; -
FIG. 13B is a cross sectional diagram taken along line XIIIB-XIIIB inFIG. 13A ; -
FIG. 14 is a plan view diagram illustrating a relief portion in accordance with a second modification of the exemplary embodiment; -
FIG. 15 is a plan view diagram illustrating a relief portion in accordance with a third modification of the exemplary embodiment; -
FIG. 16 is a plan view diagram illustrating a relief portion in accordance with a fourth modification of the exemplary embodiment; -
FIG. 17A a cross sectional diagram illustrating an adhesive member prior to pressing in accordance with a fifth modification of the exemplary embodiment; and -
FIG. 17B a cross sectional diagram illustrating the adhesive member after the pressing in accordance with the fifth modification of the exemplary embodiment. - An exemplary embodiment is described below with reference to the accompanying drawings. In the followings, as an example of a sensor apparatus, a heat type flow amount sensor apparatus is explained.
- There will be described below a heat type flow
amount sensor apparatus 100 with reference toFIGS. 1A to 1C . A heat type flowamount sensor apparatus 100 includes asensor chip 30 for detecting a flow amount of air, ahousing 40 for receiving thesenor chip 30,multiple wires 60, multiple leads 70, and a moldedmember 50. Themultiple wires 60 are electrically connected with thesensor chip 30 by wire bonding and function as an electric conductive member. The multiple leads 70 are electrically connected to themultiple wires 60, respectively. The moldedmember 50 is formed by molding using a molding material, and covers a connection part where themultiple lead 70 and the multiple wire are connected with each other. Alternatively, the multiple leads 70 may be anexternal element 70. - As shown in
FIGS. 2A and 2B , thesensor chip 30 is formed using asemiconductor substrate 30 a and formed in a thin-walled plate shape. Thesensor chip 30 includes a sensingmember 32 for sensing a flow amount of air. The sensingmember 32 is located on afront surface 30 b of thesemiconductor substrate 30 a and located near aside surface 36 d (i.e., a fourth side surface) of thesensor chip 30. Thesensor chip 30 further includesmultiple pads 34 that function as a terminal 34. Themultiple pad 34 are located on thefront surface 30 b, located near a side surface 36 c (i.e., a third side surface) of thesensor chip 30, and aligned along the side surface 36 c. Hereinafter, aside surface 36 d side is also referred on a first end side, and a side surface 36 c side is also referred on a second end side. - The
pads 34 are electrically connected with theleads 70 through thewires 60, respectively. The leads 70 are electrically connected to a control circuit (not shown) which performs a control operation based on a signal from the sensingmember 32. The sensingmember 32 has acavity 35 on a back surface thereof. The sensingmember 32 includes amembrane member 31 having a thin insulating film on a surface defining thecavity 35. - In the present embodiment, a
silicon substrate 30 a is used as thesemiconductor substrate 30 a since an insulating layer or a conductive layer can be easily formed and processed. Further, thecavity 35 is formed through etching the back surface of thesemiconductor substrate 30 a, and thereby to form themembrane member 31, since processing can be easily performed. Further, the moldedmember 50 is formed through injection molding with epoxy resin, taking into account high dimensional stability, high resistance to water and chemical, and high electric insulation. Further, thehousing 40 is formed through processing (e.g., etching) the same material as that used for theleads 70, since it becomes possible to improve production efficiency. - As shown in
FIG. 3A , thehousing 40 is formed in a generally frame shape and defines a receive space 41 (i.e., receive portion 41) for receiving thesensor chip 30. An opening 45 a (i.e., a first opening) is formed on a front surface of thehousing 40. Anotheropening 45 b (i.e., a second opening) is formed on a back surface of the housing. Theopenings 45 a, 45 b are in communication with the receivespace 41. Thehousing 40 has abonding member 44 located on a part of the bottom of the receivespace 41 on the second end side. The bondingmember 44 is bonded to a part of the back surface of thesensor chip 30 on the second end side. - The bonding
member 44 extends from a lower part of aninner side wall 42 c, which is located on the second end side, of thehousing 40 toward the first end side of thehousing 40. Asurface 44 a of thebonding member 44 is formed in a shape corresponding to the part of the back surface of thesensor chip 30 on the second end side. - That is, as shown in
FIG. 1B , thesensor chip 30 is received in the receivespace 41. The part of the back surface of thesensor chip 30 on the second end side is bonded to thesurface 44 a of thebonding member 44 using anadhesive member 80. Thesensor chip 30 is cantilevered in the receivespace 41; a bonded end of thesensor chip 30 is supported and the other end is a free end. - Accordingly, it becomes possible to reduce a bonded area. Thus, even if there exists a difference in coefficient of thermal expansion between the
sensor chip 30 and thebonding member 44, a thermal stress acting on thesensor chip 30 becomes small, and as a result, it is possible to suppress warpage, strain, and crack in thesensor chip 30. - Thus, it is possible to prevent the disordering of air conducting around the sensing
member 32, thereby to restrict reduction of detection accuracy for a flow amount of air. Further, it is possible to prevent generation of a piezoresistance effect resulting form the warpage or strain of thesensor chip 30, thereby to prevent reduction of detection accuracy of a flow amount of air. - A depth “D2” from an upper end of the opening 45 a to the
surface 44 a of thebonding member 44 is designed deeper compared to a thickness “D1” of thesensor chip 30. The depth “D2” is designed such that, when the part of the back surface of thesensor chip 30 on the second end side is placed on thesurface 44 a of thebonding member 44 via the adhesive member (referred by thereference numeral 80 inFIG. 1A to 1C ), the front surface of thesensor chip 30 projects from or positioned above the front surface of thehousing 40. - Further, as shown in
FIG. 1B and 1C , the depth “D2” is designed such that, when theadhesive member 80 placed on thesurface 44 a of theadhesive member 80 is pressed and deformed through pressing the front surface of thesensor chip 30, the front surface of thesensor chip 30 and the front surface of thehousing 40 can become in the same plane. - The receive
space 41 is formed to have such a size that thesensor chip 30 can be accommodated in the receivespace 41 through the opening 45 a while the back surface of thesensor chip 30 is being directed to thebonding member 44. As shown inFIG. 4 , the receivespace 41 has a size such that a clearance is formed between an inner side wall of the housing defining the receivespace 41 and a side surface of thesensor chip 30 received in the receive space. - A clearance 43 a is formed between a first part of a
side surface 36 a of thesensor chip 30 and a first part of an inner side wall 42 a of thehousing 40, which face each other. The side surface 36 a is generally parallel to a longer side direction of thesensor chip 30. The first part of theside surface 36 a is located closer to thepad 34 than the other part of theside surface 36 a is, and, the first part of theside surface 36 a extends to thebonding member 44. - A
clearance 43 b is formed between a first part of aside surface 36 b of thesensor chip 30 and a first part of aninner side wall 42 b of thehousing 40, which face each other. The side surface 36 a and theside surface 36 b of thesensor chip 30 are positioned opposite to each other. The first part of theside surface 36 b is located closer to thepad 34 than the other part of theside surface 36 b is. Also, the first part of theside surface 36 b extends to thebonding member 44. - A clearance 43 e is formed between a second part of the
side surface 36 a of thesensor chip 30 and a second part of the inner side wall 42 a of thehousing 40, which face each other. The second part of theside surface 36 a is located closer to the sensingmember 32 than the first part of theside surface 36 a is. - A
clearance 43 f is formed between a second part of theside surface 36 b of thesensor chip 30 and a second part of theinner side wall 42 b of thehousing 40, which face each other. The second part of theside surface 36 b is located closer to the sensingmember 32 than the first part of theside surface 36 b is. - Another clearance 43 c is formed between a side surface 36 c of the
sensor chip 30 and aninner side wall 42 c of thehousing 40, which face each other. The side surface 36 c is located on apad 34 side. - Another clearance 43 d is formed between a
side surface 36 d of thesensor chip 30 and aninner side wall 42 d of thehousing 40, which face each other. Theside surface 36 d is located on a sensingmember 32 side. - A
relief portion 41 a (i.e., an in-flow portion 41 a) is formed between theside surface 36 a of thesensor chip 30 and the inner side wall 42 a of thehousing 40, which face each other. Arelief portion 41 b (i.e., an in-flow portion 41 b) is formed between theside surface 36 b of thesensor chip 30 and theinner side wall 42 b of thehousing 40, which face each other. Therelief portions adhesive member 80 can flow into therelief portions pad 34 side. In other words, therelief portions inner side walls 42 a, 42 b, each of which extends across aboundary part 50 b of a covered portion 50 a of the molded member 50 (seeFIG. 1A ). - The
relief portion adhesive member 80 that is pushed out to theclearance 43, when thefront surface 30 b of thesensor chip 30 is pressed, by a back surface of the second end part of thesensor chip 30 and thesurface 44 a of thebonding member 44. Therelief portions adhesive member 80 flowing into theclearance 43 from reaching to the vicinity of the sensingmember 32. Further, therelief portions extra adhesive member 80 flowing into theclearance 43 from flowing to the vicinity of the sensingmember 32 via therelief portions - The
relief portions inner side walls 42 a, 42 b. In an example shown inFIG. 1A , theadhesive member 80 that had flowed in theclearance 43 partially exists in therelief portions FIG. 1B , theadhesive member 80 projects from an end face of thebonding member 44. In the present embodiment, the inner side wall defining eachrelief portion relief portions space 41. - A throttle portion 47 a is formed on the inner side wall 42 a of the
housing 40, located between the clearance 43 a and therelief portion 41 a, and located adjacent to therelief portion 41 a. Athrottle 47 b is formed between theclearance 43 b and therelief portion 41 b, and located adjacent to therelief portion 41 b. That is, thethrottle portions 47 a, 47 b are respectively formed in conduction path of theadhesive member 80 from theclearances 43 a, 43 b to therelief portions - The
throttle portions 47 a, 47 b can throttle flows of theadhesive member 80 from theclearances 43 a, 43 b toward therelief portions throttle portion 47 a, 47 b limits a flow of theadhesive member 80 to reduce an amount of theadhesive member 80 flowing to therelief portion adhesive member 80 flowing to theclearances 43 a, 43 b, 43 c. Thereby, theadhesive member 80 can move upward in theclearances 43 a, 43 b, 43 c, and can reach upper ends of theclearances 43 a, 43 b, 43 c. - The
throttle portion 47 a, 47 b can also function as a positioning member for positioning thesensor chip 30 when thesensor chip 30 is accommodated in the receivespace 41 By placing thesensor chip 30 in receivespace 41 with reference to thethrottle portions 47 a, 47 b, it is possible to reduce a positioning error of a width of eachclearance 43 a, 43 b, 43 c. In the present embodiment, the inner side wall of thehousing 40 defining each of thethrottle portions 47 a, 47 b projects toward an inside of the receivespace 41, and has a circular arc shape in a plan view. The inner side walls defining thethrottle portions 47 a, 47 b are located symmetrically with respect to the receivespace 41. - The
adhesive member 80 used has such a volume that, when theadhesive member 80 is pushed out by the part of the back surface of thesensor chip 30 on the second end and thesurface 44 a of thebonding member 44, theadhesive member 80 reaches an upper end of eachclearance 43 a, 43 b, 43 c, which are adjacent to the covered portion 50 a. That is, when thesensor chip 30 is pressed using a pressing apparatus in a pressing step of manufacturing, a surface of thesensor chip 30, a surface of thehousing 40, and a surface of theadhesive member 80 in eachclearances 43 a, 43 b, 43 c become in the same plane at theboundary part 50 b of the covered portion 50 a (seeFIGS. 1B and 1C ). - That is, the surfaces of the
sensor chip 30, thehousing 40, and theadhesive member 80 in eachclearance 43 a, 43 b, 43 c are prevented from forming a step at theboundary part 50 b. Accordingly, when the moldedmember 50 is formed by injection molding through injecting a molding material toward the covered portion 50 a, it is possible to prevent formation of a clearance between: a lower surface of a mold used in molding; and the surfaces of thesensor chip 30, thehousing 40, and theadhesive member 80. As a result, the molding material may not be leaked from the clearance, and the leaked molding material may not be attached to thesensor chip 30 or a surface of thehousing 40. Therefore, a buffer member that is conventionally used is not necessary, and thus, it is possible improve a production yield of the heat type flowamount sensor apparatus 100. It is also possible to improve production efficiency. - In the present embodiment, an adhesive member having a film shape is used as an adhesive member since control of a volume, a size and a shape is easy and since positioning on a bonding area is easy. For example, a non-conductive film (NCF) made of epoxy resin may be used as an adhesive member having a film shape since the NCF has a high rate of thermal hardening and an insulating property. The NCF has an adhesive layer on a bonding plane, and the adhesive layer is soft under ambient temperatures and becomes hard when temperature reaches a curing temperature.
- As shown in
FIG. 1B , in a portion other than the covered portion 50 a, a surface of thesensor chip 30 and a surface of thehousing 40 are also in the same plane. Thus, air flowing around the sensingmember 32 may not be disordered. As a result, it is possible improve detection accuracy of a flow amount of air. - There will be described below a
sensor chip 30 with reference toFIG. 5 . -
Heaters membrane member 31 of thesensor chip 30. Theheater 32 a is located on an upstream side of an air flow, which is shown as the outline arrow “F1” inFIG. 5 . Theheater 32 b is located on a downstream side of the air flow. Themembrane member 31 and the pair ofheaters member 32. Thesensor chip 30 further includestemperature sensors temperature sensor amount sensor apparatus 100. - Since the
membrane member 31 is much thinner than thesemiconductor substrate 30 a, themembrane member 31 has a small heat capacity, and thermal insulation of themembrane member 31 from thesemiconductor substrate 30 a is ensured. Further, since theheaters membrane member 31, the sensingmember 32 has a high sensitivity. - In the present embodiment, an insulating film is formed on a surface of the silicon substrate. The insulating film is, for example, a silicon nitride film or a silicon oxide film. On a surface of the insulating film, a semiconductor layer that is formed through thermal diffusion of impurities in a silicon layer is patterned. By using the semiconductor layer, the
heaters temperature sensors - That is, an SOI substrate is used to provide the silicon substrate, the insulating film and the semiconductor layer. The SOI substrate has a support substrate as the silicon substrate, an buried oxide layer (BOX layer) as the insulating film, and a SOI layer as the semiconductor layer.
- The semiconductor layer is covered by an insulating film made of, for example, a boron-doped phospho-silicate glass (BPSG) layer. The semiconductor layer is electrically connected with the
pads 34 a to 34 f through contact holes formed at predetermined positions of the insulating film. Thepads 34 a to 34 f are made of, for example, aluminum. - A silicon nitride film is formed on a surface of the insulating film so as to cover a generally whole of the silicon substrate, thereby to protect a surface of the
sensor chip 30. Openings are formed on the silicon nitride film at positions that respectively correspond to thepads 34 a to 34 f. Through the openings, thepads 34 a to 34 f are connected to thewires 60 by wire bonding, and thereby, thepads 34 a to 34 f are electrically connected with theleads 70. - There will be described below an operation of a heat type flow amount sensor apparatus. The
heaters leads 70. For example, the control circuit controls theheaters heaters temperature sensors heater 32 a via thepads heater 32 b via thepads heater heaters - In the above, the heat is radiated from the
heaters heaters heaters heaters heaters heater 32 a located at the upstream side radiates much more heat and requires much more electric current, compared to theheater 32 b located at the downstream side. Based on this difference, it is possible to sense the direction of the air flow as well as a flow amount of air. Thetemperature sensors - Here, the direction of air flow is assumed to be that shown as the outline arrow “F1” in
FIG. 5 . In this situation, since theheater 32 a radiates much heat as described above, the control circuit increases electric conduction to theheater 32 a to maintain temperature or resistance of theheater 32 a at a constant value. Since the air heated by theheater 32 a passes over theheater 32 b, the heat radiated from theheater 32 b becomes small, and the control circuit reduces electric conduction to theheater 32 b. Based on an amount of the electric conduction to theheater 32 a and that to theheater 32 b, it becomes possible to detect an flow amount of air and a direction of air flow. - The
heater heater heater sensor chip 30 on the second end side is bonded and fixed to thehousing 40; a part other than the bonded portion is exposed in the receivespace 41; and the exposed part are not in contact with any member. It is therefore possible to detect a flow amount with high accuracy. - There will be described below a method of manufacturing the above heat type flow
amount sensor apparatus 100 with reference to the drawings. - At S1, the above-described
housing 40 is prepared. At S2, anadhesive member 80 is placed on asurface 44 a of abonding member 44 of thehousing 40 prepared at S1, as shown inFIGS. 7A and 7B . In the present embodiment, theadhesive member 80 is placed on thesurface 44 a of thebonding member 44 by using, for example, a collet, which is used for placing an IC chip on a printed circuit board. An area of theadhesive member 80 is formed smaller than an area of thesurface 44 a. Further, theadhesive member 80 is placed on thesurface 44 a of thebonding member 44 so that theadhesive member 80 and theinner side walls housing 40 defineclearances 46 a, 46 b, 46 c therebetween. - In the above, the
adhesive member 80 is placed so that the clearances, which are defined between theadhesive member 80 and theinner side walls clearances 43 a, 43 b, 43 c will be evenly filled with theadhesive member 80 when thefront surface 30 b of thesensor chip 30 is pressed in a later process S4. - At S3, as shown in
FIGS. 8A and 8B , thesensor chip 30 is placed on theadhesive member 80 that is placed on thesurface 44 a of thebonding member 44. More specifically, thesensor chip 30 is placed so that a part of the back surface of thesensor chip 30 on a pad (34 a to 34 f) side is bonded to theadhesive member 80. In the above, it is possible to easily position thesensor chip 30 in the receivespace 41 by using athrottle portion 47 a, 47 b (which functions as a positioning portion as described) as a mark to determine a position of thesensor chip 30. Further, it is possible to reduce an error of the width of eachclearance 43 a, 43 b, 43 c. - At S4, the front surface of the sensor chip is pressed. As shown in
FIG. 8B , a pressing apparatus for pressing the front surface of thesensor chip 30 includes a pressingmember 90. The pressingmember 90 has a built-inheater 95, and a flatpressing surface 90 a on a lower surface thereof. Thepressing surface 90 a is made of a material that theadhesive member 80 is hard to be attached to. In the present embodiment, the pressingmember 90 is made of, for example, metal, resin, ceramic or the like. Further, a surface of the pressing member corresponding to the pressing surface is coated by Teflon (registered trademark). Alternatively, the pressing member may be made of Teflon. - As shown in
FIG. 8B , thefront surface 30 b of thesensor chip 30 placed on thebonding member 44 projects from the front surface of thehousing 40. When thefront surface 30 b of thesensor chip 30 is pressed by the pressingmember 90, theadhesive member 80 is pressed and deformed by the back surface of thesensor chip 30 and thesurface 44 a of thebonding member 44. The pushed and deformedadhesive member 80 partially flows into theclearances 43 a, 43 b, 43 c and moves upward in eachclearance 43 a, 43 b, 43 c. Then, as shown inFIGS. 9A and 9B , the pressing is stopped when thepressing surface 90 a of the pressingmember 90 contacts the front surface 40 a of thehousing 40. -
FIG. 9B is a cross sectional taken along line in a thickness direction of thesensor chip 30, the line passing through theboundary part 50 b of the covered portion 50 a. As shown inFIG. 9B , the following surfaces are in the same plane: thefront surface 30 b of thesensor chip 30; the front surface 40 a of thehousing 40; thesurface 80 a of theadhesive member 80 that is located in the clearance 43 a; thesurface 80 b of theadhesive member 80 that is located in theclearance 43 b; and the surface of theadhesive member 80 that is located in the clearance 43 c. That is, at theboundary part 50 b of the covered portion 50 a, the surfaces of thesensor chip 30, thehousing 40 and theadhesive member 80 are in the same plane and do not have a step. Although a part of the adhesive member flowing into theclearances 43 a, 43 b, 43 c further flows toward the sensingmember 32, thethrottle portions 47 a, 47 b restricts the flow toward the sensingmember 32 en route to the sensingmember 32. - As a result, a large part of the
adhesive member 80 flows in theclearances 43 a, 43 b, 43 c, and reaches an upper end of eachclearance 43 a, 43 b, 43 c. When theclearances 43 a, 43 b, 43 c are filled with theadhesive member 80, theadhesive member 80 may spread beyond thethrottle portions 47 a, 47 b. In such a case, theadhesive member 80 spreading beyond thethrottle portions 47 a, 47 b flows in and are trapped in therelief portions adhesive member 80 therefore does not reach the vicinity of the sensingmember 32. - In the covered portion 50 a, the
adhesive member 80 moving upward in eachclearance 43 a, 43 b, 43 c stops to further move upward owing to the presence of thepressing surface 90 a of the pressingmember 90. Theadhesive member 80 therefore cannot leak to the front surface of thesensor chip 30 and the front surface of thehousing 40. - Upon finishing the pressing of the sensor chip by using the pressing
member 90, theheater 95 activates in a state where thefront surface 30 b of thesensor chip 30 is pressed by thepressing surface 90 a. The heat generated by theheater 95 conducts to theadhesive member 80 via thesensor chip 30, and causes theadhesive member 80, which has a thermosetting property, to harden. Since thesensor chip 30 is formed using the silicon substrate having a high thermal conductivity, theadhesive member 80 hardens in a moment. - At S5, each
pad 34 a to 34 f of thesensor chip 30 is electrically connected to a corresponding one of the leads 70. In the present embodiment, the electrical connection between the eachpad 34 a to 34 f and thecorresponding lead 70 is made using thewire 60 by wire bonding, as shown inFIGS. 10A and 10B . Alternatively, thepads 34 a to 34 f may be electrically connected with a printed circuit board instead of thelead 70, depending on an external element to which the heat type flow amount sensor apparatus is to be connected. In such a case, by ultrasonic welding, thepads 34 a to 34 f may be electrically connected to the printed circuit board with stud bumps. - At S6, a portion 94 a (referred to hereinafter as a film cover portion) including the
boundary part 50 b of the covered portion 50 a is covered with afilm 94 made of synthetic resin, as shown inFIGS. 10A and 10B . At S7, as shown inFIG. 11A , the members formed through S1 to S6 are placed in a mold space 93 (space for forming the moldedmember 50 by injection molding through injecting a molding material) defined by alower part 92 of a mold. Then, as shown inFIG. 11B , anupper part 91 of the mold is connected to thelower part 92 of the mold to close the mold. - In the above, a lower surface 91 a of the
upper part 91 of the mold has a part that corresponds to the covered portion 50 a and that defines themold space 93. The other part of the lower surface 91 a of theupper part 91 contacts a part of the front surface 40 a of thehousing 40 and a part of thefront surface 30 b of thesensor chip 30, wherein the part of thefront surface 30 b and the part of the front surface 40 a extends from theboundary part 50 b to the film covered portion 94 a. Similarly, an upper surface 92 a of thelower part 92 of the mold has a part that corresponds to the covered portion 50 a and that defines themold space 93. The other part of the upper surface 92 a contacts a part of the back surface of thehousing 40 and a part of the back surface of thesensor chip 30, wherein the parts of the back surfaces of thehousing 40 corresponds to the other part of the lower surface 91 a of theupper part 91 of the mold. - As S8, as shown in
FIG. 11C , a molding material is injected into themold space 93 to fill themold space 93 with the molding material. In the above, the front surface of thesensor chip 30, the front surface of thehousing 40, and a surface of theadhesive member 80 reaching an upper end of theclearance 43 a, 43 b are in the same plane at theboundary part 50 b of the covered portion 50 a, as shown inFIG. 9B . Thus, a gap is not formed between the lower surface 91 a of theupper part 91 of the mold and the above-described surfaces being in the same plane. The injected molding material cannot spread and cannot leak to the front surface 40 a of thehousing 40 beyond theboundary part 50 b. - There may exist a possibility that the side surfaces 36 a, 36 b have irregularities resulting from, for example, a process of forming the
sensor chip 30 by dicing a semiconductor substrate. However, since the irregularities are filled with theadhesive member 80, the molding material cannot leak out via the irregularities. This commonly happens when theinner side walls 42 a, 42 b of thehousing 40 have irregularities. - Here, it is assumed that, as shown in
FIG. 12A , the front surface 40 a of thehousing 40 has a flaw in a concave shape at a part crossing theboundary part 50 b. At S6, thefilm 94 covers the flaw 40 b, as shown inFIG. 12B . Then, a pressure applied when the mold is closed presses and deforms the film located between the lower surface 91 a of theupper part 91 of the mold and the front surface 40 a of the housing, and then, the flaw 40 b is filled with thefilm 94, as shown inFIG. 12C . - Accordingly, the molding material injected into the
mold space 93 at S8 cannot spread and cannot reach thefront surface 30 b of thesensor chip 30 and the front surface 40 a of thehousing 40 beyond theboundary part 50 b. Further, when thefront surface 30 b of thesensor chip 30 has a flaw at a portion extending across theboundary part 50 b, the flow is filled with thefilm 94, and thus, the molding material cannot leak out via the flaw. Further, when asurface 80 a or asurface 80 b (seeFIG. 9B ) of theadhesive member 80 has a flaw at a portion extending across theboundary part 50 b, the flaw is also filled with thefilm 94, and thus, the molding material cannot leak out via the flaw. - When the
front surface 30 b of thesensor chip 30 and the front surface 40 a of the housing form a step therebetween at a portion extending across theboundary part 50 b owing to a dimensional tolerance of thehousing 40 or thesensor chip 30, the step is covered with thefilm 94, and thus, the molding material cannot leak out via the step. When the lower surface 91 a of theupper part 91 of the mold has a flaw at a portion extending across theboundary part 50 b, the flaw is filled with thefilm 94, and thus, the molding material cannot leak out via the flaw. - When another factor other then the flaw in a concave shape, such as a foreign element having a convex shape, exists at the
boundary part 50 b, the foreign element is absorbed or covered by thefilm 94 and does not form a gap, and thus, the foreign element cannot be a factor for leaking the molding material. - At S9, a surface of the mold corresponding to the
mold space 93 is cooled, and the molding material filling in themold space 93 hardens. Then, at S10, theupper part 91 of the mold is moved upward to open the mold. At S11, the heat type flowamount sensor apparatus 100 is removed from themold space 93, as shown inFIG. 11D . - According to the heat type flow
amount sensor apparatus 100 and the method of manufacturing the same, a gap is not formed at theboundary part 50 b of the covered portion 50 a when the covered portion 50 a is formed using the molding material by injection molding, and thus, the molding material cannot leak to a region other than the covered portion. It is possible to prevent leak of the molding material without using a buffering member, which is used in a conventional manner. Thus, it is possible to improve a production yield and production efficiency of a heat type flow amount sensor apparatus. - (Modifications)
- The above embodiment can be modified and extended in various ways. Examples of modifications will be described below.
- (First Modification)
- A position, a shape and a size of the relief portion, and the number of relief portions can be changed as long as the pushed out adhesive member cannot reach the vicinity of the sensing
member 32. - For example, as shown in
FIGS. 13A and 13B , theinner side wall 42 c of thehousing 40 located on apad 34 side may defines relief portions 43 g arranged at predetermined intervals each. Each relief portion 43 g has a ditch shape and is in communication with the clearance 43 c and extends in a direction away from the sensingmember 32. According to the above structure, it is possible to move an extra part of the adhesive member, which is pressed, deformed and pushed out by thesenor chip 30 and thehousing 40, in a direction away from the sensingmember 32. - (Second Modification)
- As shown in
FIG. 14 , theinner side wall 42 c of thehousing 40 on apad 34 side may defines relief portions 43 h each formed in a circular arc shape in a plan view. According to the above structure, it is possible to provide an advantage generally identical to that of the first modification. - (Third Modification)
- As shown in
FIG. 15 , the inner side wall 42 a of thehousing 40 defining the clearance 43 a may further defines multiple relief portions 43 i each having a ditch shape and each extending outwardly. Further, theinner side wall 42 b of thehousing 40 defining theclearance 43 b may further defines multiple relief portions 43 i each having a ditch shape and each extending outwardly. According to the above structure, it is possible to provide an advantage generally identical to that of the first modification. - (Fourth Modification)
- As shown in
FIG. 16 , the inner side wall 42 a of thehousing 40 defining the clearance 43 a may further defines multiple relief portions 43 j each having a circular arc shape in a plan view and each extending outwardly. Further, theinner side wall 42 b of thehousing 40 defining theclearance 43 b may further defines multiple relief portions 43 i each having a circular arc shape in a plan view each extending outwardly. According to the above structure, it is possible to provide an advantage generally identical to that of the first modification. - In the first, third and fourth modifications, since the
inner side wall 42 c on apad 34 side does not define a relive portion, it is possible to reduce a gap between thepads 34 and the leads 70. - (Fifth Modification)
-
FIG. 17A is a cross sectional diagram illustrating the adhesive member prior to pressing in accordance with a fifth modification.FIG. 17B is a cross sectional diagram illustrating the adhesive member after the pressing in accordance with the fifth modification. As shown inFIG. 17A , although the adhesive member is located between thesensor chip 30 and thebonding member 44, both end parts of theadhesive member 80 respectively reach theinner side walls 42 a, 42 b of thehousing 40. Further, otheradhesive members 81 thinner than theadhesive member 80 are respectively located on surfaces of both end parts of theadhesive member 80. - The
adhesive members 81 are respectively formed in sizes so that, when thesensor chip 30 is placed on theadhesive member 80, theadhesive members 81 can placed inclearances 43 a, 43 b between the side surfaces of thesensor chip 30 and theinner side walls 42 a, 42 b of thehousing 40. By placing theadhesive members 81 on both end parts of the surface of theadhesive member 80, a thickness given by theadhesive members adhesive member 80 located on the back surface of thesensor chip 30. - As shown in
FIG. 17B , thefront surface 30 b of thesensor chip 30 is pressed by thepressing surface 90 a of the pressingmember 90, and then, theadhesive member 80 is pressed and deformed, and the pressedadhesive member 80 partially flows in theclearances 43 a, 43 b. Thereby, eachadhesive member 81 moves upward until contacting thepressing surface 90 a, and theclearances 43 a, 43 b are filled. - According to the above manners, it is possible to supply shortage of, if it occurs, the adhesive member that flows in the
clearances 43 a, 43 b and possible to reliably close eachclearance 43 a, 43 b, by further placing theadhesive members 81 on theadhesive member 80 exposed in theclearances 43 a, 43 b, which are between the side surfaces of thesensor chip 30 and the inner side walls of thehousing 40. - Alternatively, the
adhesive members sensor chip 30 may be placed on a bottom of the concave shape of the adhesive member. - (Other Modifications)
- (I) The adhesive member may be placed on a part of the back surface of the
sensor chip 30 that corresponds to thesurface 44 a of thebonding member 44, and thesensor chip 30 may be placed on thesurface 44 a of thebonding member 44. - (II) The
housing 40 that defines the receive space having a closed bottom may be used, and the part of thesensor chip 30 on the second end side may be bonded to a part of the bottom of the receive space on the second end side. - (III) The throttle portions may be formed on each of three or four inner side walls of the
housing 40. In such a case, it becomes possible to more easily position thesensor chip 30, and possible to improve the positioning accuracy. - (IV) The above embodiments can be applied to not only a heat flow amount sensor apparatus but various sensor apparatuses in which a sensing member is exposed. The various sensor apparatuses include a pressure sensor apparatus, a humidity sensor apparatus, a solar radiation sensor apparatus, an infrared sensor apparatus and the like.
- The above embodiments and the modifications have the following aspects.
- According to a first aspect, a method of manufacturing a sensor apparatus is provided. The method includes: preparing a
sensor chip 30 including asubstrate 30 a, a sensingmember 32 located on thesubstrate 30 a, and a terminal 34 a to 34 f located on thesubstrate 30 a and configured to output a signal from the sensingmember 32; and preparing ahousing 40. Thehousing 40 has (i) a first opening 45 a on a front surface thereof, (ii) an inner side wall 42 a to 42 d defining a receivespace 41 therein communicating with the first opening 45 a, and (iii) abonding member 44 located on an inner bottom surface of thehousing 40 at aboundary part 50 b of a predetermined portion 50 a. The inner bottom surface defines a bottom of the receivespace 41. A depth D2 defined between the first opening 45 a and thebonding member 44 is deeper compared to a thickness D1 of thesensor chip 30. The method further includes: placing anadhesive member 80 on one of thebonding member 44 and a back surface of thesensor chip 30; and placing thesensor chip 30 in the receivespace 41 through the first opening 45 a so that the sensingmember 32 is exposed. The placing of thesensor chip 30 includes placing the back surface of thesensor chip 30 on thebonding member 44 via theadhesive member 80 to form aclearance 43 between aside surface 36 a to 36 d of thesensor chip 30 and the inner side wall 42 a to 42 d of thehousing 40. The method further includes: pressing the front surface of thesensor chip 30 whose back surface is placed on thebonding member 44, so that: thesensor chip 30 and thehousing 40 push theadhesive member 80 to theclearance 43; and the front surface of thesensor chip 30, the front surface of thehousing 40 and a surface of a part of theadhesive member 80 pushed in theclearance 43 are in a same plane at theboundary part 50 b. The method further includes: electrically connecting the terminal 34 a to 34 f to an electricalconductive member 60, the electricalconductive member 60 to be electrically connected to anexternal element 70; and forming, by injection molding, a moldedmember 50 that covers the predetermined portion 50 a including a connection part where the terminal 34 a to 34 f and the electricconductive member 60 are connected with each other. The forming of the moldedmember 50 includes: closing a mold receiving thesensor chip 30, thehousing 40 and the electricconductive member 60, after the pressing of the front surface of thesensor chip 30 and the electrically connecting of the terminal 34 a to 34 f; and injecting a molding material in the mold. - According to a second aspect, a sensor apparatus is provided that includes: a
sensor chip 30 including asubstrate 30 a, a sensingmember 32 located on thesubstrate 30 a, and a terminal 34 a to 34 f located on thesubstrate 30 a and configured to output a signal from the sensingmember 32; ahousing 40 receiving thesensor chip 30 with the sensingmember 32 of thesensor chip 30 being exposed; an electricconductive member 60 electrically connected with the terminal 34 a to 34 f and to be electrically connected with anexternal element 70; and a moldedmember 50 covering a covered portion 50 a including a connection portion where the terminal 34 a to 34 f and the electricconductive member 60 are connected with each other. Thehousing 40 has a first opening 45 a on a front surface thereof. Thehousing 40 defines a receivespace 41 therein (i) communicating with the first opening 45 a and (ii) receiving thesensor chip 30 through the first opening 45 a while thehousing 40 and aside surface 36 a to 36 d of thesensor chip 30 define aclearance 43 therebetween. Thehousing 40 further has abonding member 44. The bondingmember 44 is located on an inner bottom surface of thehousing 40 at a place corresponding to aboundary part 50 b of the covered portion 50 a, the inner bottom surface defining a bottom of the receivespace 41. The bondingmember 44 is bonded to a back surface of thesensor chip 30 via anadhesive member 80. The first opening 45 a and thebonding member 44 define therebetween a depth D2, the depth D2 being deeper compared to a thickness D1 of thesensor chip 30. A part of theadhesive member 80 is located in theclearance 43 by being pressed and pushed out by thesensor chip 30 and thehousing 40. The front surface of thehousing 40, a surface of the part of theadhesive member 80, and a front surface of thesensor chip 30 are in a same plane at theboundary part 50 b. - According to the above sensor apparatus and the manufacturing method, when the front surface of the sensor chip placed on the bonding member of the housing is pressed, the adhesive member placed between the back surface of the sensor chip and the bonding member is partially pushed out and flows in the clearance between the side surface of the sensor chip and the inner side wall of the housing. Then, the surface of the part of the adhesive member flowing in the clearance, the front surface of the sensor chip, and the front surface of the housing are in the same plane at the boundary part of the covered portion (i.e., predetermined portion).
- Accordingly, in injecting the molding material into the predetermined portion, a gap is not formed between the mold and the above surfaces, and thus, the molding material cannot leak a region other than the covered portion (i.e., a predetermined portion). Thus, it is possible to prevent the leak of the molding material without using a buffer member, which is used in a conventional manner. It is possible to improve a production yield of the sensor apparatus. Further, it is possible to improve production efficiency of the sensor apparatus.
- According to a third aspect, a method of manufacturing a sensor apparatus is provided. The method includes: preparing a
sensor chip 30 including asubstrate 30 a, a sensingmember 32 located on thesubstrate 30 a, and a terminal 34 a to 34 f located on thesubstrate 30 a and configured to output a signal from the sensingmember 32; and preparing ahousing 40. Thehousing 40 has (i) a first opening 45 a on a front surface of thehousing 40, (ii) an inner side wall 42 a to 42 d defining a receivespace 41 therein communicating with the first opening 45 a, and (iii) abonding member 44 located on an inner bottom surface of thehousing 40 at aboundary part 50 b of a predetermined portion 50 a. The inner bottom surface defines a bottom of the receivespace 41. A depth D2 defined between the first opening 45 a and thebonding member 44 is deeper compared to a thickness D1 of thesensor chip 30. The method further includes: placing anadhesive member 80 on one of thebonding member 44 and a back surface of thesensor chip 30; placing thesensor chip 30 in the receivespace 41 through the first opening 45 a so that the sensingmember 32 is exposed. The placing of thesensor chip 30 includes placing the back surface of thesensor chip 30 on thebonding member 44 via theadhesive member 80 to form aclearance 43 between aside surface 36 a to 36 d of thesensor chip 30 and the inner side wall 42 a to 42 d of thehousing 40. The method further includes: pressing the front surface of thesensor chip 30 whose back surface is placed on thebonding member 44, so that thesensor chip 30 and thehousing 40 push theadhesive member 80 to theclearance 43; electrically connecting the terminal 34 a to 34 f to an electricalconductive member 60, the electricalconductive member 60 to be electrically connected to anexternal element 70; placing afilm 94 on the front surface of thesensor chip 30 and the front surface of thehousing 40 so that thefilm 94 covers theboundary part 50 b of the predetermined portion 50 a, after the pressing of the front surface of thesensor chip 30 and the electrically connecting of the terminal 34 a to 34 f; and forming, by injection molding, a moldedmember 50 that covers the predetermined portion 50 a including a connection part where the terminal 34 a to 34 f and the electricconductive member 60 are connected with each other. The forming of the moldedmember 50 includes: closing a mold receiving thesensor chip 30, thehousing 40 and the electricconductive member 60, after the pressing of the front surface of thesensor chip 30 and the electrically connecting of the terminal 34 a to 34 f; and injecting a molding material in the mold. - When the sensor chip or the housing has tiny irregularities on surfaces at a boundary part of a predetermined portion, one may suppose that a gap is formed between the mold and the surfaces and the molding material would leak via the irregularities in forming the molded member through injecting the molding material into the predetermined portion. According to the above manufacturing method, however, the mold is closed in a state where the film is formed on the front surface of the sensor chip and the front surface of the housing so as to cover the boundary part. The irregularities are filled with the film owing to pressure of the closing of the mold, and as a result, the gap disappears.
- Accordingly, in injecting the molding material into the predetermined portion, a gap between the mold and the above surfaces does not exist there is not. Thus, the molding material cannot leak a region other than the covered portion (i.e., a predetermined portion). It is possible to prevent the leak of the molding material without using a buffer member, which is used in a conventional manner. It is possible to improve a production yield of the sensor apparatus. Further, it is possible to improve production efficiency of the sensor apparatus.
- Further, even if, at the boundary part of the predetermined portion, there is formed irregularities resulting from a step between the above surfaces (i.e., the surface the part of the adhesive member flowing in the clearance, the front surface of the sensor chip, and the front surface of the housing, the irregularities can be filled with the film. Therefore, the molding material cannot the leak via the step.
- The manufacturing method according to the third aspect may further have the following feature. The
film 94 is placed so as to cover: theboundary part 50 b; the sensingmember 32; a part of thesensor chip 30 between theboundary part 50 b and the sensingmember 32; and the front surface of thehousing 40. - Accordingly, the film can function as a buffer member to protect a surface of the sensor chip and a surface of the housing from damage due to contact with the mold in the closing the mold.
- The manufacturing method according to the first or third aspect may further have the following feature. The
inner side wall 42 a, 42 b of thehousing 40 defines an in-flow portion adhesive member 80 pushed to theclearance 43. - The sensor apparatus according to the second aspect may further has the following feature. The
housing 40 has an inner side wall 42 a to 42 d defining theclearance 43, and theinner side wall 42 a, 42 b of thehousing 40 further defines an in-flow portion adhesive member 80 pushed out to theclearance 43. - According to the above manners, the in-flow portion is formed on the inner side wall, which defines the clearance, of the housing. The adhesive member pushed to the clearance can flow into the in-flow portion. Thereby, since it is possible to flow an extra part of the adhesive member into the in-flow portion, it is possible limit flow of the adhesive member in the clearance. The extra part of the adhesive member cannot leak from the clearance to the surface of the sensor chip or the surface of the housing.
- The
above adhesive member 80 may have a volume such that the part of theadhesive member 80 pushed to theclearance 43 flows in the in-flow portion sensor chip 30 is pressed. - When there is a variation in volume of the clearance at the boundary part, there is a variation in volume of the adhesive member required to fill the clearance at the boundary part. If the variation exists, when an amount of the adhesive member is determined in accordance with a minimum volume of the clearance, the surface of the adhesive member filling the clearance may be positioned lower than the surface of the sensor chip and the surface of the housing, owing to shortage of the adhesive member.
- According to the above manner, however, even if there is a variation in the volume of the clearance, it is possible to reliably fill the clearance with the adhesive member, since: a volume of the adhesive member is set such that: the part of the
adhesive member 80 pushed to theclearance 43 flows in the in-flow portion sensor chip 30 is pressed. In other words, the volume of the adhesive member is set such that the, even if the adhesive member fills the clearance at the boundary part, the adhesive member still has an extra part that is to flow into the in-flow part. Therefore, it is not necessary to control a size of the sensor chip and a size of the housing with high accuracy. It is possible to further improve a production yield of the sensor apparatus. Further, it is possible to further improve production efficiency of the sensor apparatus. - The manufacturing method according to the first aspect or the third aspect may further have the following features. The side surface 36 a to 36 d of the
sensor chip 30 includes afirst side surface 36 a, asecond side surface 36 b and a third side surface 36 c. The first and second side surfaces 36 a, 36 b are opposite to each other, and are continuously connected to a first end and a second end of the third side surface 36 c, respectively. The third side surface 36 c is located on a terminal 34 a to 34 f side. The inner side wall 42 a to 42 d of thehousing 40 includes a first inner side wall 42 a facing thefirst side surface 36 a of thesensor chip 30 and a secondinner side wall 42 b facing thesecond side surface 36 b of thesensor chip 30. Thefirst side surface 36 a of thesensor chip 30 and the first inner side wall 42 a of thehousing 40 define therebetween afirst clearance 43 included in theclearance 43. Thesecond side surface 36 b of thesensor chip 30 and the secondinner side wall 42 b of thehousing 40 define therebetween asecond clearance 43 included in theclearance 43. The first inner side wall 42 a and the secondinner side wall 42 b of thehousing 40 respectively define a first in-flow portion 41 a and a second in-flow portion 41 b included in the in-flow portion. - The sensor apparatus according to the second aspect may further have the following features. The side surface 36 a to 36 d of the
sensor chip 30 includes afirst side surface 36 a, asecond side surface 36 b and a third side surface 36 c. The first and second side surfaces 36 a, 36 b are opposite to each other, and are continuously connected to a first end and a second end of the third side surface 36 c, respectively. The third side surface 36 c is located on a terminal 34 a to 34 f side. The inner side wall 42 a to 42 d of thehousing 40 includes a first inner side wall 42 a facing thefirst side surface 36 a of thesensor chip 30 and a secondinner side wall 42 b facing thesecond side surface 36 b of thesensor chip 30. Thefirst side surface 36 a of thesensor chip 30 and the first inner side wall 42 a of thehousing 40 define therebetween afirst clearance 43 included in theclearance 43. Thesecond side surface 36 b of thesensor chip 30 and the secondinner side wall 42 b of thehousing 40 define therebetween asecond clearance 43 included in theclearance 43. The first inner side wall 42 a and the secondinner side wall 42 b of thehousing 40 respectively define a first in-flow portion 41 a and a second in-flow portion 41 b included in the in-flow portion. - According the above features, since the clearance includes the first and second clearances, the adhesive member pushed by the sensor chip and the bonding member flows along the first and second side surfaces of the sensor chip. Accordingly, since the first and second in-flow portions are respectively formed on the first and second inner side walls of the housing, the adhesive member flowing along the first and second side surfaces of the sensor chip can flow into the first and second in-flow portions, respectively. As a result, it is possible to restrict a variation in volume of the adhesive member between that flowing along the first side surface of the sensor chip and that flowing along the second side surface, and it is possible to prevent the adhesive member from leaking to a portion of the front surface of the housing on one of a first clearance side or a second clearance side.
- The above manufacturing method according to the third aspect may further have the following features. The inner side wall 42 a to 42 d of the
housing 40 includes a thirdinner side wall 42 c facing the third side surface 36 c of thesensor chip 30. The third side surface 36 c of thesensor chip 30 and the thirdinner side wall 42 c of thehousing 40 define therebetween athird clearance 43 included in theclearance 43. The thirdinner side wall 42 c defines a third in-flow portion - The above sensor apparatus according to the second aspect may further have the following features. The inner side wall 42 a to 42 d of the
housing 40 includes a thirdinner side wall 42 c facing the third side surface 36 c of thesensor chip 30. The third side surface 36 c of thesensor chip 30 and the thirdinner side wall 42 c of thehousing 40 define therebetween athird clearance 43 included in theclearance 43. The thirdinner side wall 42 c defines a third in-flow portion - According to the above manufacturing method or sensor apparatus, the adhesive member flowing in the third clearance can further flow into the third clearance. As a result, it is possible to prevent the adhesive member flowing in the third clearance from leaking to a portion of the front surface of the housing on one of a first clearance side or a second clearance side.
- The above manufacturing method according to the third aspect or the above sensor apparatus according to the second aspect may alternatively have the following features. The inner side wall 42 a to 42 d of the
housing 40 includes a thirdinner side wall 42 c facing the third side surface 36 c of thesensor chip 30; the third side surface 36 c of thesensor chip 30 and the thirdinner side wall 42 c of thehousing 40 define therebetween athird clearance 43 included in theclearance 43. The thirdinner side wall 42 c does not define the in-flow portion - According to the above method or the above sensor apparatus, since the in-flow portion is not formed on the third inner side wall of the housing, the in-flow portion cannot be an obstacle for electrical connection of the terminal to the electric conductive member.
- The manufacturing method according to the first or third aspect and the sensor apparatus according to the second aspect may further have the following features. The sensing
member 32 of thesensor chip 30 outputs a signal that depends on a flow amount of air. The pressing of the front surface of thesensor chip 30 includes causing the front surface of thesensor chip 30 and the front surface of thehousing 40 to be in the same plane. - When the sensing member is used for outputting a signal that depends on a flow amount of air, it is desirable that the air flowing around the sensing member be not disordered. According the above method and sensor apparatus, since the pressing the sensor chip causes the front surface of the sensor chip and the front surface of the housing to be in the same plane, the front surface of the sensor chip and the front surface of the housing does not form a gap, which can be a factor for disordering the air flowing around the sensing member.
- The method according to the first or third aspect may further have the following features. The inner side wall 42 a to 42 d of the
housing 40 defines apositioning portion 47 a, 47 b for positioning thesensor chip 30 in the receivespace 41 of thehousing 40. In the placing of thesensor chip 30 in the receivespace 41, thesensor chip 30 is positioned with reference to thepositioning portion 47 a, 47 b. - The sensor apparatus according to the second aspect may have the following features. The inner side wall 42 a to 42 d of the
housing 40 defines apositioning portion 47 a, 47 b for use in positioning thesensor chip 30 in the receivespace 41 of thehousing 40. - According the above manufacturing method and the above sensor apparatus, it is possible to easily position the sensor chip on the bonding member of the housing with reference to the positioning portion formed on the inner side wall of the housing. Positioning of the sensor chip becomes easy.
- The above manufacturing method and the above sensor apparatus may further have the following features. The inner side wall 42 a to 42 d of the
housing 40 defines, at a region between theboundary part 50 b and the in-flow portion, athrottle portion 47 a, 47 b that restricts a flow of the part of theadhesive member 80 in theclearance 43. - According to the above manufacturing method and the above sensor apparatus, since it is possible to restrict the flowing of the adhesive member in the clearance toward the in-flow portion, the adhesive member can readily flow in the clearance toward the surface. Therefore, at the boundary part, the adhesive member can be filled with the clearance and can reach the upper end of the clearance reliably, and thus, it is possible to eliminate a gap at the boundary part.
- The above manufacturing method may further have the following features. The
throttle portion 47 a, 47 b provides thepositioning portion 47 a, 47 b. In the placing of thesensor chip 30 in the receivespace 41, thesensor chip 30 is positioned with reference to the positioning part. - The above sensor apparatus may further have the following feature: the
throttle portion 47 a, 47 b provides thepositioning portion 47 a, 47 b. - According the above manufacturing method and the sensor apparatus, since the
throttle portion 47 a, 47 b can function as thepositioning portion 47 a, 47 b, it is necessary to form thethrottle portion 47 a, 47 b and thepositioning portion 47 a, 47 b separately. It is possible to further improve production efficiency of the sensor apparatus. - The manufacturing method according to the first and third aspects, and the sensor apparatus according to the second aspect may further have the following features. The back surface of the
sensor chip 30 has a first part at an end of thesensor chip 30, the first part corresponding to theboundary part 50 b. The first part of the back surface is bonded to thebonding member 44 of thehousing 40. Another part of the back surface of thesensor chip 30 other than the first part is spaced apart from the bottom of the receivespace 41. - According the above manufacturing method and the sensor apparatus, the first part of the back surface of the sensor chip is bonded to the bonding member, and a part of the sensor chip other than the first part is spaced apart of the bottom of the receive space. It is thus possible reduce a bonded area of the sensor chip. Therefore, even if the sensor chip and the housing are made of materials having different coefficients of thermal expansion, it becomes possible to reduce thermal stress acting on the sensor chip, and thus, it is possible to prevent generation of warpage, strain or crack in the sensor chip.
- In particular, when the sensing member is one that detects a flow amount of air, it is possible to restrict reduction of detection accuracy of the flow amount of air. Further, when the sensor chip is configured such that an electric path for electrically connecting the sensing member and an external control circuit is formed on the sensor chip, a piezoresistive effect resulting from the warpage or strain in the sensor chip may cause a change of an electric signal traveling on the electric path and may reduce the detection accuracy.
- According to the above manufacturing method and the sensor apparatus, however, it is possible to reduce the warpage and the strain in the sensor chip, and therefore, the reduction of detection accuracy resulting from a piezoresistive effect can be prevented.
- The manufacturing method according to the first and third aspects, and the sensor apparatus according to the second aspect may further have the following feature: the inner bottom surface of the
housing 40 has a second opening at a region other than the bondingmember 44. - According to the above manufacturing method and the sensor apparatus, since a part of the bottom of the receive space other than the bonding member is opened, a front surface and a back surface of the sensing member is exposed to a common environment.
- The manufacturing method according to the first aspect and the third aspect may further have the following features. The
adhesive member 80 includes a thermosettingadhesive member 80. The pressing of the front surface of thesensor chip 30 includes: heating the adhesive member to harden the adhesive member. - The sensor apparatus according to the second aspect may further has the following features. The
adhesive member 80 includes a thermosettingadhesive member 80. - According to the above manufacturing method and sensor apparatus, by pressing the front surface of the sensor chip that is placed on the bonding member via the adhesive member, it is possible to push out the adhesive member by the sensor chip and the housing, possible to flow into the clearance, and possible to harden the adhesive member by heating.
- The manufacturing method according to the first aspect and the third aspect and the sensor apparatus according to the second aspect may further have the following feature: the
adhesive member 80 has a film shape. - According to the above manufacturing method and the sensor apparatus, since the adhesive member has a film shape, the adhesive member is easy to deal and easy to be placed on the back surface of the sensor chip or the bonding member.
- The manufacturing method according to the first aspect and the third aspect may further have the following feature: the
substrate 30 a includes asilicon substrate 30 a. - According to the above manufacturing method and sensor apparatus, since the substrate includes the silicon substrate, it is possible to form and process an insulating layer and a conductive layer with ease. Further, since the silicon substrate has a high thermal conductivity, it is possible to harden the thermosetting adhesive member at a moment by heating the surface of the silicon substrate.
- The manufacturing method according to the first aspect and the third aspect may further have the following aspect: in the pressing of the front surface of the
sensor chip 30, apressing surface 90 a of a pressingmember 90 presses the front surface of thesensor chip 30, thepressing surface 90 a having an resistance to attachment of theadhesive member 80 thereto. - According to the above manufacturing method, since the font surface of the sensor chip is pressured by the pressing member having the pressing surface with the resistance to attachment of the adhesive member, it is possible to prevent the adhesive member from attaching to the pressing surface. Further, it is possible to prevent the housing from attaching the pressing member via the adhesive member.
- In the above manufacturing method, the
pressing surface 90 a may be a planer surface. - In such a case, it is possible to, by pressing the front surface of the sensor chip, the following area be in the same plane: a surface of the adhesive member that projects from the clearance at the boundary part of the predetermined portion; the front surface of the sensor chip; and the front surface of the housing.
- When the pressing of the front surface of the sensor chip stops at a time the pressing surface of the pressing member contacts the front surface of the housing, it is possible to make the front surface of the sensor chip and the front surface of the housing be in the same plane.
- In particular, when the sensing member is one that detects a flow amount of air, since a step is not formed between the front surface of the sensor chip and the front surface of the housing, it is possible to efficiently prevent the air flowing around the sensing member from being disordered. It is therefore possible to improve detection accuracy.
- While the invention has been described above with reference to various embodiments thereof, it is to be understood that the invention is not limited to the above described embodiments and construction. The invention is intended to cover various modifications and equivalent arrangements. In addition, while the various combinations and configurations described above are contemplated as embodying the invention, other combinations and configurations, including more, less or only a single element, are also contemplated as being within the scope of embodiments.
Claims (33)
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JP2008030319A JP4577370B2 (en) | 2008-02-12 | 2008-02-12 | Sensor device and manufacturing method thereof |
JP2008-30319 | 2008-02-12 | ||
JP2008-030319 | 2008-11-26 |
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US20090199632A1 true US20090199632A1 (en) | 2009-08-13 |
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US12/320,957 Active US7712203B2 (en) | 2008-02-12 | 2009-02-10 | Method of manufacturing a sensor apparatus |
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Also Published As
Publication number | Publication date |
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JP4577370B2 (en) | 2010-11-10 |
JP2009192238A (en) | 2009-08-27 |
DE102009008183A1 (en) | 2009-08-13 |
US7712203B2 (en) | 2010-05-11 |
DE102009008183B4 (en) | 2017-08-31 |
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